Methods of making fibrous structures with shaped polymer particles

ABSTRACT

A fibrous structure comprising first and second plies. The first ply comprises a first textured substrate comprising a first side comprising first discrete regions and a first continuous region extending between the first discrete regions, each first discrete region comprising an outer section and sidewall sections extending outwardly from the adjacent first continuous region to the outer section; a second side comprising first discrete portions corresponding to the first discrete regions and a first continuous portion corresponding to the first continuous region; and first polymer particles deposited on at least one of the first side or the second side. When the first polymer particles are deposited on the first side, the first polymer particles are substantially deposited on the outer sections of the first discrete regions and do not extend to the adjacent first continuous region. When the first polymer particles are deposited on the second side, the first polymer particles are substantially deposited on the first continuous portion and do not extend to the adjacent first discrete portions. At least a section of each of the first polymer particles defines a raised edge. The second ply comprises a second substrate joined to the first textured substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority under 35U.S.C. § 120 to, U.S. patent application Ser. No. 16/200,736, filed onNov. 27, 2018, which claims the benefit, under 35 USC § 119(e), of U.S.Provisional Patent Application Ser. No. 62/610,316, filed on Dec. 26,2017, the entire disclosures of which are fully incorporated byreference herein.

FIELD

The present disclosure is directed to methods of making fibrousstructures, and more particularly to methods of making fibrousstructures comprising polymer particles selectively formed on one ormore areas of the fibrous structure.

BACKGROUND

Products made from a fibrous web are used for a variety of purposes. Forexample, paper towels, facial tissues, toilet tissues, napkins, and thelike are in constant use in modern industrialized societies. The largedemand for such paper products has created a demand for improvedversions of the products. If the paper products such as paper towels,facial tissues, napkins, toilet tissues, mop heads, and the like are toperform their intended tasks and to find wide acceptance, they mustpossess certain physical characteristics.

Among the more important of these characteristics are strength,softness, absorbency, and cleaning ability. Strength is the ability of apaper web to retain its physical integrity during use. Softness is thepleasing tactile sensation consumers perceive when they use the paperfor its intended purposes. Absorbency is the characteristic of the paperthat allows the paper to take up and retain fluids, particularly waterand aqueous solutions and suspensions. The absolute quantity of fluid agiven amount of paper will hold is important, but also the rate at whichthe paper will absorb the fluid. Cleaning ability refers to a fibrousstructures' capacity to remove and/or retain soil, dirt, or body fluidsfrom a surface, such as a kitchen counter, or body part, such as theface or hands of a user.

However, also important in today's retail environment is the appearanceof a paper towel or bath tissue. That is, in addition to superiorperformance properties of a fibrous structure, retail consumers desirethe product to be visually appealing. Thus, manufacturers of fibrousstructures such as paper towels and bath tissue must produce productsthat both perform well, and have consumer-acceptable aestheticqualities.

Often the two goals of superior product performance and desirableaesthetics are in contradiction to one another. For example, absorbencyor strength in a paper towel may depend on processing parameters such asthe structure of papermaking belts during paper making or the embosspattern applied during converting operations. Both paper structuresproduced during papermaking and embossing may affect the physicalproperties of the finished product, but they also affect the visual,aesthetic properties. It may happen that a fibrous structure in the formof a paper towel, for example, may have superior absorbency propertiesin a visually un-aesthetic manner, while a paper towel with visualappeal and softness may have reduced strength and/or cleaning ability.

Accordingly, there is a need for new fibrous structures that deliverboth superior performance properties, particularly cleaning of dried-onor adhered soils, and consumer-desirable aesthetic properties.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a portion of an example textured substrate inaccordance with the present disclosure;

FIGS. 2A and 2B are cross-sectional views taken along line 2-2 of thetextured substrate of FIG. 1;

FIGS. 2C and 2D are cross-sectional views additional examples texturedsubstrates in accordance with the present disclosure;

FIG. 2E is a cross-sectional view of an example textured substrate inaccordance with the present disclosure;

FIGS. 3A-3C are enlarged cross-sectional views of a portion of thetextured substrate of FIG. 2A comprising polymer particles;

FIG. 3D is an enlarged cross-sectional view of a portion of the texturedsubstrate of FIG. 2B comprising polymer particles;

FIG. 4 is a plan view of a portion of another example textured substratein accordance with the present disclosure;

FIG. 5A is a cross-sectional view taken along line 5-5 of the texturedsubstrate of FIG. 4;

FIG. 5B is a cross-sectional view, similar to FIG. 5A, of an additionalexample textured substrate in accordance with the present disclosure;

FIG. 6 is an enlarged cross-sectional view of a portion of either of thetextured substrates of FIG. 5A or 5B;

FIG. 7 is a plan view of a portion of another example textured substratein accordance with the present disclosure;

FIG. 8A is a cross-sectional view taken along line 8-8 of the texturedsubstrate of FIG. 7;

FIG. 8B is a cross-sectional view, similar to FIG. 8A, of an additionalexample textured substrate in accordance with the present disclosure;

FIG. 9 is a schematic view of a slot coater;

FIG. 10 is a detailed view of a portion of the slot coater of FIG. 9;

FIGS. 11A-11E are detailed plan views of a portion of a first side of anexample textured substrates comprising polymer particles in accordancewith the present disclosure;

FIG. 12A is a cross-sectional view taken along the line 12-12 of one ofthe polymer particles of FIG. 11A;

FIG. 12B is a cross-sectional view, similar to FIG. 12A, of anadditional example polymer particle in accordance with the presentdisclosure;

FIG. 13 is a cross-sectional view taken along line 13-13 of one of thepolymer particles of FIG. 11D;

FIG. 14 is a detailed plan view of a portion of a second side of anexample textured substrates comprising polymer particles in accordancewith the present disclosure;

FIG. 15A is a cross-sectional view taken along the line 15-15 of one ofthe polymer particles of FIG. 14;

FIG. 15B is a cross-sectional view, similar to FIG. 15A, of anadditional example polymer particle in accordance with the presentdisclosure;

FIGS. 16A-16C are cross-sectional views of example fibrous structureswith multiple plies of textured substrates comprising polymer particlesin accordance with the present disclosure;

FIG. 17 is an example process for making a textured substrate accordingto the present disclosure; and

FIG. 18 is a flowchart illustrating an exemplary method for forming afibrous structure comprising a textured substrate according to thepresent disclosure.

DETAILED DESCRIPTION

Various non-limiting embodiments of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the fibrous structuresdisclosed herein. One or more examples of these non-limiting embodimentsare illustrated in the accompanying drawings. Those of ordinary skill inthe art will understand that the fibrous structures described herein andillustrated in the accompanying drawings are non-limiting exampleembodiments and that the scope of the various non-limiting embodimentsof the present disclosure are defined solely by the claims. The featuresillustrated or described in connection with one non-limiting embodimentmay be combined with the features of other non-limiting embodiments.Such modifications and variations are intended to be included within thescope of the present disclosure.

“Fibrous structure” as used herein means a structure that comprises oneor more plies, each comprising one or more fibers, such as paper.Non-limiting examples of processes for making fibrous structures includeknown wet-laid papermaking processes and air-laid papermaking processes,and embossing and printing processes. Such processes typically comprisethe steps of preparing a fiber composition in the form of a suspensionin a medium, either wet, more specifically aqueous medium, or dry, morespecifically gaseous (i.e., with air as medium). The aqueous medium usedfor wet-laid processes is oftentimes referred to as a fiber slurry. Thefibrous suspension is then used to deposit a plurality of fibers onto aforming wire or papermaking belt such that an embryonic fibrousstructure may be formed, after which drying and/or bonding the fiberstogether results in a fibrous structure. During the manufacturingprocess, visually distinct features may be produced in the finishedfibrous structure, as described herein. Any of the various forming wiresand papermaking belts utilized may be designed to leave a physical,three-dimensional impression in the finished paper. Suchthree-dimensional impressions are well known in the art, particularly inthe art of “through air drying” (TAD) processes. The term “texturedsubstrate” is used herein to refer to one ply of a fibrous structurecomprising these three-dimensional impressions, wherein the fibrousstructure may comprise one or more textured substrates.

Further processing of the fibrous structure may be carried out such thata finished fibrous structure is formed. The fibrous structure may alsoundergo one or more finishing steps such as embossing, laminating,calendering, printing, winding, cutting, and/or packaging. For example,in typical papermaking processes, the finished fibrous structure is thefibrous structure that is wound on the reel at the end of papermakingand may subsequently be converted into a finished product (e.g., asanitary tissue product). Embossing is typically performed by one of twoprocesses: knob-to-knob embossing, in which protuberances on axiallyparallel rolls juxtaposed to form a nip therebetween are registered withprotuberances on the opposing roll, and nested embossing, in which theprotuberances of one roll mesh between the protuberances of the otherroll. Examples of knob-to-knob embossing and nested embossing areillustrated in U.S. Pat. Nos. 3,414,459; 3,547,723; 3,556,907;3,708,366; 3,738,905; 3,867,225; and 4,483,728. U.S. Pat. No. D239,137illustrates an emboss pattern found on commercially successful papertoweling.

“Machine Direction” or “MD” as used herein means the direction on a webcorresponding to the direction parallel to the flow of a fibrous web orfibrous structure through a fibrous structure making machine.

“Cross Machine Direction” or “CD” as used herein means a directionperpendicular to the Machine Direction in the plane of the web.

“Relatively low density” as used herein means a portion of a fibrousstructure having a density that is lower than a relatively high-densityportion of the fibrous structure. The relatively low density may be inthe range of 0.02 g/cm³ to 0.09 g/cm³, for example, relative to a highdensity that may be in the range of 0.1 to 0.13 g/cm³.

“Relatively high density” as used herein means a portion of a fibrousstructure having a density that is higher than a relatively low-densityportion of the fibrous structure. The relatively high density may be inthe range of 0.1 to 0.13 g/cm³, for example, relative to a low densitythat may be in the range of 0.02 g/cm³ to 0.09 g/cm³.

“Discrete region” or “discrete portion” as used herein means a discretearea, i.e., a portion of a papermaking belt or fibrous structure definedor surrounded by, or at least partially defined or surrounded by, asubstantially continuous deflection conduit or substantially continuousregion that has an enclosed perimeter.

“Substantially continuous” as used herein with respect to high- orlow-density networks means the network fully defines or surrounds moreof the discrete regions or discrete deflection elements than itpartially defines or surrounds.

“Semicontinuous” as used herein with respect to high- or low-densitynetworks means the network extends substantially throughout onedirection of the network, and each region in the network is spaced apartfrom adjacent regions. Examples of structures for forming semicontinuouspatterns are described in U.S. Pat. No. 5,628,876.

The present disclosure relates to a fibrous structure comprising aplurality of discrete regions and a plurality of continuous regions. Insome aspects, the discrete regions may be relatively high density, andthe continuous regions may be relatively low density. In other aspects,the discrete regions may be relative low density, and the continuousregions may be relatively high density. The fibrous structure maycomprise one or more plies, each comprising a textured substrate.Polymer particles may be formed on a plurality of the discrete regions,a plurality of the continuous regions, or both.

The fibrous structures of the present disclosure may be in the form ofsanitary tissue product rolls. Such sanitary tissue product rolls cancomprise a plurality of connected, but perforated sheets of one or moreplies, that are separably dispensable from adjacent sheets, such as isknown for paper towels and bath tissue, which are both consideredsanitary tissue products when in roll form. The fibrous structures ofthe present disclosure may comprises additives such as softening agents,temporary wet strength agents, permanent wet strength agents (such aspolyamido-amino-epichlorohydrine (PAE) polymers), bulk softening agents,lotions, silicones, wetting agents, latexes, especiallysurface-pattern-applied latexes, dry strength agents (such ascarboxymethylcellulose, starches, or polyacrylamide polymers), and othertypes of additives suitable for inclusion in and/or on sanitary tissueproducts and/or fibrous structures.

FIG. 1 is a plan view of a portion of an exemplary one-ply texturedsubstrate 100, which could define a single-ply fibrous structure or oneply of a multi-ply fibrous structure. FIGS. 2A and 2B arecross-sectional views taken along line 2-2 of FIG. 1. With reference toFIGS. 1, 2A, and 2B, the textured substrate 100, 100′ comprises a firstside 102, 102′ and a second side 104, 104′. The first side 102, 102′ ofthe respective textured substrate 100, 100′ comprises a plurality ofdiscrete regions 106, 106′ and a continuous region 108, 108′ extendingbetween the discrete regions 106, 106′. In the example shown in FIG. 1,the continuous region 108, 108′ may comprise a substantially continuousnetwork in which discrete regions 106, 106′ are dispersed throughout thesubstantially continuous network. The textured substrate 100, 100′ alsocomprises transition regions 114, 114′ positioned intermediate thediscrete regions 106, 106′ and the continuous region 108, 108′. One ofthe transition regions 114, 114′ at least partially encircles each ofthe discrete regions 106, 106′. The second side 104, 104′ of eachtextured substrate 100, 100′ comprises a plurality of discrete portions110, 110′ corresponding to the discrete regions 106, 106′ on the firstside 102, 102′ and a continuous portion 112, 112′ corresponding to thecontinuous region 108, 108′ on the first side 102, 102′.

In some examples, as shown in FIG. 2A, the discrete regions 106 andcorresponding discrete portions 110 may comprise a relativelyhigh-density zone 124, and the continuous region 108 and correspondingcontinuous portion 112 may comprise a relatively low-density zone 126.In other examples, as shown in FIG. 2B, the discrete regions 106′ andcorresponding discrete portions 110′ may comprise a relativelylow-density zone 126′, and the continuous region 108′ and correspondingcontinuous portion 112′ may comprise a relatively high-density zone124′. The low-density zones 126, 126′ are depicted throughout theFigures as having a greater thickness than adjacent high-density zones124, 124′.

The exemplary textured substrates 100, 100′ depicted in FIGS. 1, 2A, and2B may comprise a wet-laid fibrous structure ply and may be formed usingone or more deflection members, such as a deflection member formed froma foraminous secondary belt 121 coated with resin to provide athree-dimensional structure, for example, as described in U.S. Pat. Nos.4,528,239; 5,334,289; and 5,628,876 (see also FIG. 17). Accordingly, thedeflection member may comprise a plurality of raised portions. Eachraised portion of the deflection member forms a correspondinghigh-density zone 124, 124′ in the respective textured substrate 100,100′. The deflection member may further include deflection conduits,i.e., areas of the foraminous secondary belt where holes are present andresin does not completely block the holes, for forming the low-densityzones 126, 126′. The exemplary textured substrates 100, 100′ shown inFIGS. 2A and 2B may be formed by transferring an embryonic web (see FIG.17) onto the deflection member such that the discrete regions 106, 106′extend outwardly on one side, i.e., the first side 102, 102′, from arespective surface plane P₁, P_(1′) of the textured substrates 100,100′. Hence, a deflection member would contact the second side 104 so asto form the discrete regions 106 in the textured substrate 100 of FIG.2A and a deflection member would contact the first side 102′ so as toform the continuous regions 104′ in the textured substrate 100′ of FIG.2B.

In some examples, the raised portions of the deflection member maycomprise discrete elements that would correspondingly form thehigh-density discrete regions 106 and discrete portions 110 of thetextured substrate 100, as shown in FIG. 2A. A shape and/or pattern ofthe high-density discrete regions 106 and discrete portions 110 may beat least partially defined by a shape and/or pattern of the raisedportions of the deflection member comprising discrete elements. Whilethe discrete regions 106 in FIG. 1 are illustrated as comprising aplurality of uniformly spaced hexagons, it is to be understood that oneor more other shapes or patterns may also be formed. For example, thediscrete regions 106 (when viewed from the direction of arrow A in FIG.2A) may be substantially circular, ovate (see FIGS. 11A-11C), square(see FIG. 11E), diamond-shaped (see FIG. 4), trapezoidal, or any othersuitable polygonal shape (not shown unless otherwise noted). Thediscrete regions 106 may be uniformly spaced, modulated (i.e.,non-uniform but organized), or randomly spaced.

In addition, one or more of a size of the discrete elements of thedeflection member or a spacing therebetween may be adjusted to achieve adesired spacing and ratio of a surface area comprising the discreteregions 106 to a surface area comprising the continuous region 108. Forexample, as shown in FIG. 2E, a width W₁₀₆ of the discrete regions 106may be decreased, such that a spacing between the discrete regions 106is increased and the ratio of the discrete region surface area to thecontinuous region surface area is decreased, as compared to the examplesshown in FIGS. 2A and 2B. In other examples, a width W₁₀₈ of thecontinuous region 108 of the textured substrate 100A may be increased.In further examples (not shown), the width W₁₀₆ of the discrete regions106 may be increased or the width W₁₀₈ of the continuous region 108 maybe decreased, such that the spacing between the discrete regions 106 isdecreased and the ratio of the discrete region surface area to thecontinuous region surface area is increased, as compared to the examplesshown in FIGS. 2A and 2B. In yet further examples, both the width W₁₀₆of the discrete regions 106 and the width W₁₀₈ of the continuous region108 may be altered.

In other examples, the raised portions of the deflection member may forma continuous network, which would correspondingly form the high-densitycontinuous region 108′ and continuous portion 112′ of the texturedsubstrate 100′, as shown in FIG. 2B. A shape and/or pattern of thehigh-density continuous region 108′ and the corresponding continuousportion 112′ may be at least partially defined by the shape and/orpattern of the raised portions of the deflection member comprising acontinuous network. As shown in FIG. 2B, the high-density continuousregions 108′ may comprise a substantially planar section 146 that issubstantially co-planar with the surface plane P_(1′) of the texturedsubstrate 100′. The high-density continuous portions 112′ may comprise asubstantially planar area 148 corresponding to the substantially planarsection 146.

In all examples, a shape of the low-density zones 126, 126′ may be atleast partially defined by the shape of the continuous network of raisedportions on the deflection member and/or by the deflection conduit(s),both of which may comprise any suitable shape and/or pattern. Forexample, with reference to FIGS. 1 and 2B, at least a portion of thelow-density discrete regions 106′, e.g., the transition regions 114′,may comprise a substantially hexagonal shape, when viewed from the firstsurface 102′ (i.e., from the direction of arrow A in FIG. 2A). Thishexagonal shape may be at least partially defined by the pattern ofraised portions on the deflection member that are used to form thehigh-density continuous regions 108′.

In the exemplary textured substrates 100, 100′ depicted in FIGS. 1, 2A,and 2B, a plurality of the discrete regions 106, 106′ may comprise anouter section 116, 116′ and sidewall sections 118, 118′ extendingoutwardly from the continuous region 108, 108′ to the respective outersection 116, 116′ of each discrete region 106, 106′. For example, aplurality of the discrete regions 106, 106′ may comprise protrusionsthat extend or protrude from the respective surface plane P₁, P_(1′) ofthe textured substrates 100, 100′ toward an imaginary observer lookingin the direction of arrow A of FIG. 2A (i.e., looking at the firstsurface 102, 102′). As shown in FIGS. 2A and 2B, the surface planes P₁,P_(1′) may be at least partially defined by the continuous regions 108,108′ and continuous portions 112, 112′ of the respective texturedsubstrates 100, 100′. When viewed by an imaginary observer looking inthe direction indicated by arrow B of FIG. 2A (i.e., looking at thesecond surface 104, 104′), the plurality of discrete portions 110, 110′may appear to be recesses, cavities, or dimples. In some particularaspects, a shape of the outer section 116 of the high-density discreteregions 106 may be at least partially defined by the shape of the raisedportions of the deflection member. In some examples, as shown in FIG.2A, the outer section 116 may be substantially planar and may begenerally co-planar with the surface plane P₁ of the textured substrate100. In other examples, the discrete region 106 may comprise adome-shaped outer section 140, as shown in FIG. 2C, or a concave outersection 142, as shown in FIG. 2D.

FIGS. 3A-3C are enlarged views of a portion of the textured substrate100 of FIG. 2A comprising polymer particles 120, 130 deposited on one orboth of the first side 102 or the second side 104 of the texturedsubstrate 100, as described herein in detail. As shown in FIG. 3A, insome instances, the polymer particles 120 may be deposited only on thefirst side 102 of the textured substrate 100. In other instances, thepolymer particles 130 may be deposited only on the second side 104 asshown in FIG. 3B. As shown in FIG. 3C, in further instances, polymerparticles 120, 130 may be deposited on both the first side 102 and thesecond side 104 of the textured substrate 100.

FIG. 3D is an enlarged view of a portion of the textured substrate 100′of FIG. 2B comprising polymer particles 120′, 130′. Similar to theexamples shown in FIGS. 3A-3C, the polymer particles 120′, 130′ in theexemplary textured substrate 100′ of FIG. 3D may be deposited only onthe first side 102′ of the textured substrate 100′, only on the secondside 104′ of the textured substrate 100′, or on both the first side 102′and the second side 104′ of the textured substrate 100′.

FIG. 4 is a plan view of a portion of another exemplary one-ply texturedsubstrate 200, which could define a single-ply fibrous structure or oneply of a multi-ply fibrous structure. FIG. 5A is a cross-sectional viewtaken along line 5-5 in FIG. 4, and FIG. 5B is a cross-sectional view,similar to FIG. 5A, of an additional exemplary textured substrate 200′.Each of the textured substrates 200, 200′ in FIGS. 4, 5A, and 5Bcomprises a first side 202, 202′ and a second side 204, 204′. The firstside 202, 202′ of each textured substrate 200, 200′ comprises aplurality of discrete regions 206, 206′ and a continuous region 208,208′ extending between the discrete regions 206, 206′. The continuousregion 208, 208′ may comprise a substantially continuous network inwhich the discrete regions 206, 206′ are dispersed throughout thesubstantially continuous network. The textured substrates 200, 200′ alsocomprise transition regions 214, 214′ positioned intermediate thediscrete regions 206, 206′ and the continuous region 208, 208′. One ofthe transition regions 214, 214′ at least partially encircles each ofthe discrete regions 206, 206′. The second side 204, 204′ of eachtextured substrate 200, 200′ comprises a plurality of discrete portions210, 210′ corresponding to the discrete regions 206, 206′ on the firstside 202, 202′ and a continuous portion 212, 212′ corresponding to thecontinuous region 208, 208′ on the first side 202, 202′.

In some examples, as shown in FIG. 5A, the discrete regions 206 andcorresponding discrete portions 210 of the textured substrate 200 maycomprise a relatively high-density zone 224, and the continuous region208 and corresponding continuous portion 212 may comprise a relativelylow-density zone 226. In other examples, as shown in FIG. 5B, thediscrete regions 206′ and corresponding discrete portions 210′ of thetextured substrate 200′ may comprise a relatively low-density zone 226′,and the continuous region 208′ and corresponding continuous portion 212′may comprise a relatively high-density zone 224′. The texturedsubstrates depicted in FIGS. 4, 5A, and 5B may be formed such that thelow-density zones 226, 226′ extend outwardly on both sides 202,204/202′, 204′ from a respective surface plane P₂, P_(2′) of thetextured substrates 200, 200′.

In some examples, the exemplary textured substrates 200, 200′ depictedin FIGS. 4, 5A, and 5B may comprise a wet-laid fibrous structure ply andmay be formed using deflection members (see FIG. 17). For example, onedeflection member may comprise a plurality of raised portions that forma corresponding one of the high-density zones 224, 224′ and deflectionconduits that form a corresponding one of the low-density zones 226,226′ on one side, e.g., the first side 202, 202′, of the respectivetextured substrate 200, 200′. A second deflection member comprisingcorresponding raised portions and deflection conduits may be used toform the high-density zones, 224, 224′ and low-density zones 226, 226′on the other side, e.g., the second side 204, 204′, of the respectivetextured substrate 200, 200′. Hence, the high-density discrete regions206 and discrete portions 210 of FIG. 5A may be formed by a deflectionmember with raised portions comprising discrete elements, and the highdensity continuous region 208′ and continuous portion 212′ of FIG. 5Bmay be formed by a deflection member with raised portions that form acontinuous network, as described herein. In other examples, theexemplary textured substrates 200, 200′ depicted in FIGS. 4, 5A, and 5Bmay be formed by an embossing and/or patterned calendering process, asdescribed herein. For example, the textured substrate 200, 200′ may bepassed through a nip comprising one or more of a patterned steel roll, asmooth rubber covered roll, a smooth steel roll, and/or a patternedrubber covered roll, in which the patterns on the roll(s) form thecorresponding high-density zones 224, 224′ and low-density zones 226,226′ of the textured substrate 200, 200′. Examples these processes areillustrated in, for example, U.S. Pat. No. 3,414,459.

As previously described, a shape and/or pattern of the high-densitydiscrete regions 206 and discrete portions 210 of the textured substrate200 depicted in FIG. 5A may be at least partially defined by a shapeand/or pattern of the raised portions of deflection members comprisingdiscrete elements or by the patterns on the roll(s) used to form thetextured substrate 200. While the discrete regions 206 in FIG. 4 areillustrated as comprising a plurality of uniformly spaced diamondshapes, it is to be understood that one or more other shapes or patternsmay also be formed, as described herein. Likewise, a shape and/orpattern of the high-density continuous region 208′ and the correspondingcontinuous portion 212′ of the textured substrate 200′ depicted in FIG.5B may be at least partially defined by the shape and/or pattern of theraised portions of the deflection members or by the patterns on theroll(s) used to form the textured substrate 200′. As shown in FIG. 5B,the high-density continuous regions 208′ may comprise a substantiallyplanar section 246 that is substantially co-planar with the surfaceplane P_(2′) of the textured substrate 200′. The high-density continuousportions 212′ may comprise a substantially planar area 248 correspondingto the substantially planar section 246.

In all examples, a shape of the low-density zones 226, 226′ may be atleast partially defined by the shape of the continuous network of raisedportions on the deflection member and/or by the deflection conduits orby the patterns on the roll(s) used to form the respective texturedsubstrate 200, 200′, both of which may comprise any suitable shapeand/or pattern. For example, with reference to FIGS. 4 and 5B, at leasta portion of the low-density discrete regions 206′, e.g., the transitionregions 214′, may comprise a diamond shape (see FIG. 1) when viewed fromthe first surface 202′. This diamond shape may be at least partiallydefined by the pattern of raised portions on the deflection members thatare used to form the high-density continuous regions 208′.

FIG. 6 is an enlarged view of a portion of a textured substrate 400,which may correspond to either of the textured substrates 200, 200′depicted in FIGS. 5A and 5B. The textured substrate 400 compriseshigh-density zones 424 and low-density zones 426 and may comprise asurface plane P₃ that may be at least partially defined by thehigh-density zones 424. The textured substrate 400 may comprise polymerparticles 420, 430 deposited on one or both of the first or second sides402, 404. Similar to the examples shown in FIGS. 3A-3C, the polymerparticles 420, 430 in the exemplary textured substrate 400 of FIG. 6 maybe deposited only on the first side 402 of the textured substrate 400,only on the second side 404 of the textured substrate 400, or on boththe first side 402 and the second side 404 of the textured substrate400. In some examples, similar to the textured substrate 200 of FIG. 5A,the relatively high-density zones 424 of the textured substrate 400 maycomprise the discrete regions and the corresponding discrete portions(not separately labeled in FIG. 6), and the relatively low-density zones426 may comprise a continuous region and the corresponding continuousportion (not separately labeled in FIG. 6). In other examples, similarto the textured substrate 200′ of FIG. 5B, the relatively high-densityzones 424 of the textured substrate 400 may comprise a continuous regionand the corresponding continuous portion (not separately labeled in FIG.6), and the relatively low-density zones 426 may comprise the discreteregions and the corresponding discrete portions (not separately labeledin FIG. 6).

FIG. 7 is a plan view of a portion of another exemplary one-ply texturedsubstrate 600, which could define a single-ply fibrous structure or oneply of a multi-ply fibrous structure. FIG. 8A is a cross-sectional viewtaken along line 8-8 in FIG. 7 of the textured substrate 600 of FIG. 7,and FIG. 8B is a cross-sectional view, similar to FIG. 8A, of anotherexemplary textured substrate 600′. With reference to FIGS. 7, 8A, and8B, the textured substrate 600, 600′ comprise a first side 602, 602′ anda second side 604, 604′. The textured substrates 600, 600′ each comprisea plurality of substantially continuous or semicontinuous, relativelyhigh-density zones 624, 624′ and a plurality of substantially continuousor semicontinuous, relatively low-density zones 626, 626′. Each of thetextured substrates 600, 600′ comprise transition regions 614, 614′positioned intermediate the high-density zones 624, 624′ and thelow-density zones 626, 626′. The transition regions 614, 614′ run alongat least a portion of a longitudinal length of the respectivehigh-density zone 624, 624′.

When viewed from the direction of arrow A in FIG. 8A, the low-densityzones 626 of the textured substrate 600 may appear as a series ofsubstantially continuous or semicontinuous ridges extending outwardlyfrom a surface plane P₄ of the textured substrate 600, in which thesurface plane P₄ of the textured substrate 600 may be at least partiallydefined by the high-density zones 624. The low-density zones 626 of thetextured substrate 600 of FIG. 8A may comprise an outer section 616 andsidewall sections 618 extending outwardly from the adjacent high-densityzones 624 to the outer section 616 of the respective low-density zone626. The high-density zones 624 of the textured substrate 600, whenviewed from the direction of arrow A, may appear as a series ofsubstantially continuous or semicontinuous planar sections 646. Whenviewed from the direction of arrow B in FIG. 8A, the low-density zones626 of the textured substrate 600 may appear as a series ofsubstantially continuous or semicontinuous troughs, and the high-densityzones 624 may appear as a series of substantially continuous orsemicontinuous planar areas 648. When viewed from either of the firstside 602′ or the second side 604′, the low-density zones 626′ of thetextured substrate 600′ depicted in FIG. 8B may appear as a series ofsubstantially continuous or semicontinuous ridges extending outwardlyfrom a surface plane P4′ of the textured substrate 600′, and thehigh-density zones 624′ may appear as a series of substantiallycontinuous or semicontinuous planar sections. The surface plane P_(4′)may be at least partially defined by the high-density zones 624′.

The textured substrates 600, 600′ depicted in FIGS. 7, 8A, and 8B may beformed using any of the processes described herein. For example, thetextured substrates 600, 600′ may be formed using one or more deflectionmembers comprising a plurality of substantially continuous orsemicontinuous raised portions and a plurality of substantiallycontinuous or semicontinuous deflection conduits. The texturedsubstrates 600, 600′ may also be formed using an embossing and/orpatterned calendering process, in which the patterns on the roll(s) formthe corresponding substantially continuous or semicontinuoushigh-density and low-density zones 624, 624′, 626, 626′. The texturedsubstrates 600, 600′ of FIGS. 8A and 8B may comprise polymer particles620, 620′, 630, 630′ deposited on one or both of the first or secondsides 602, 602′, 604, 604′. Similar to the examples shown in FIGS.3A-3C, the polymer particles 620, 620′, 630, 630′ in the exemplarytextured substrates 600, 600′ shown in FIGS. 8A and 8B may be depositedonly on the first side 602, 602′ of the textured substrate 600, 600′,only on the second side 604, 604′, or on both the first side 602, 602′and the second side 604, 604′.

In all examples described herein, the polymer particles may be depositedon the textured substrate 100 using a slot coater 10, as shown in FIG.9, which may comprise a housing 12, a slot coat header 14, and a nozzle18. The textured substrate 100 shown in FIG. 9 may represent any of thetextured substrates described herein. The polymer particles 120 maylikewise represent any of the polymer particles described herein. Theslot coater 10 is coupled to a hot melt extruder 16, which supplies theslot coater 10 with a heated polymer (not separately labeled). The slotcoat header 14 and nozzle 18 may be heated to a temperature that issubstantially the same as the temperature of the heated polymer. Theheated polymer is pumped from the hot melt extruder 16 and flows throughthe slot coat header 14 and nozzle 18 onto a surface of a texturedsubstrate 100 at a substantially constant pressure and temperature toprovide a consistent polymer flow rate onto the textured substrate 100.Driven rolls (not shown) move the textured substrate 100 in thedirection indicated by the arrow C, and rollers 20 support the texturedsubstrate 100 as the nozzle 18 presses into and deflects the texturedsubstrate 100. The heated polymer is deposited by the nozzle 18 onto oneside, e.g., the first side 102, of the textured substrate 100, and aplurality of polymer particles 120 are formed as the textured substrate100 is passed across the nozzle 18 of the slot coat header 14.

The heated polymer is substantially deposited on an area of the texturedsubstrate 100 that contacts the nozzle 18. In one example, withreference to FIGS. 2A, 2B, 3A, 3D, and 9, when the first side 102, 102′of the textured substrate 100, 100′ is facing the nozzle 18, the area ofthe textured substrate 100, 100′ that contacts the nozzle 18 comprisesthe discrete regions 106, 106′, such that the heated polymer issubstantially deposited onto the discrete regions 106, 106′ when thetextured substrate 100, 100′ is passed across the nozzle 18 of the slotcoat header 14.

As described herein, the heated polymer solidifies quickly, i.e., beforethe heated polymer is able to flow into the adjacent continuous region108, 108′, such that the polymer particles 120, 120′ formed on thediscrete regions 106, 106′ do not extend to the adjacent continuousregion 108, 108′. Further, because the heated polymer is deposited basedon contact of the textured substrate 100, 100′ with the nozzle 18 of theslot coat header 14, it is believed that little or no heated polymer isdeposited on or flows to other areas of the textured substrate 100, 100′that do not contact the nozzle 18. For example, the heated polymer maybe deposited on the discrete regions 106, 106′ such that the polymerparticles 120, 120′ do not extend past the transition regions 114, 114′positioned intermediate the discrete regions 106, 106′ and the adjacentcontinuous region 108, 108′. In some instances, a plurality of thediscrete regions 106 and the corresponding discrete portions 110 maycomprises high-density zones, and the continuous region 108 andcorresponding continuous portion 112 may comprise a low-density zone, asshown in FIGS. 2A and 3A. In other instances, a plurality of thediscrete regions 106′ and the corresponding discrete portions 110′ maycomprises low-density zones, and the continuous region 108′ andcorresponding continuous portion 112′ may comprise a high-density zone,as shown in FIGS. 2B and 3D. In other examples, the heated polymer isdeposited only on the discrete regions 106, 106′.

In some particular examples, as described herein, the discrete regions106, 106′ may comprise an outer section 116, 116′ and sidewall sections118, 118′ extending outwardly from the adjacent continuous region 108,108′ and from the respective surface plane P₁, P_(1′) of the texturedsubstrate 100, 100′ to the outer section 116, 116′ of the respectivediscrete region 106, 106′. In some instances, the heated polymer may bedeposited only on the outer sections 116, 116′ of the discrete regions106, 106′. As shown in FIG. 3A, when the discrete regions 106 comprise ahigh-density zone 124 and the outer section 116 is substantially planar,the heated polymer may be deposited only on the substantially planarportion of the outer section 116. The substantially planar outer section116 contacts the nozzle 18, and it is believed that little or no heatedpolymer is deposited on other areas of the textured substrate 100 thatdo not contact the nozzle 18, e.g., the sidewalls 118 or the adjacentcontinuous region 108. In some instances, when the high-density discreteregions 106 comprise a concave outer section 142, as shown in FIG. 2D,the heated polymer may be deposited along a perimeter (not labeled; seeFIGS. 11A-C) of the concave outer section 142 and/or within the concaveouter section 142. As shown in FIGS. 2B, 2C, and 3D, the outer section116, 116′ of the discrete region 106, 106′ may comprise a dome-shapedouter section 140 (not separately labeled in FIGS. 2B and 3D), and theheated polymer may be substantially deposited on an outermost part ofthe dome-shaped outer section 140, i.e., an area of the outer portion116, 116′, 140 that is generally co-planar with the surface plane P₁,P₁′ of the respective textured substrate 100, 100′.

With reference to FIGS. 2A, 2B, 3B, and 3D, when the second side 104,104′ of the textured substrate 100, 100′ is facing the nozzle 18, thearea of the textured substrate 100, 100′ that contacts the nozzle 18comprises the continuous portion 112, 112′, such that the heated polymeris substantially deposited onto the continuous portion 112, 112′ whenthe textured substrate 100, 100′ is passed across the nozzle 18 of theslot coat header 14 (see also FIG. 10). The polymer particles 130, 130′formed on the continuous portion 112, 112′ do not extend to the adjacentdiscrete portion 110, 110′. Because the heated polymer is depositedbased on contact with the textured substrate 100, 100′, e.g., contactbetween the continuous portions 112, 112′ and the nozzle 18 andsolidifies quickly, it is believed that little or no heated polymer isdeposited on or flows to other areas of the textured substrate 100, 100′that do not contact the nozzle 18. For example, the heated polymer maybe deposited on the continuous portions 112, 112′ such that the polymerparticles 130, 130′ do not extend past transition regions 114, 114′positioned intermediate the continuous portion 112, 112′ and theadjacent discrete portions 110, 110′. In some instances, the continuousportion 112′ and the continuous region 108′ may comprise a high-densityzone, and the discrete portions 110′ and discrete regions 106′ maycomprise low-density zones, as shown in FIG. 3D. In other instances, thecontinuous portion 112 and continuous region 108 may comprise alow-density zone, and the discrete portion 110 and discrete region 106may comprise high-density zones, as shown in FIG. 3B. In some particularexamples, the heated polymer is deposited only on the continuous portion112, 112′.

With reference to FIGS. 9 and 10, after the heated polymer is depositedon one side of the textured substrate 100, e.g., the polymer particles120 are formed on the first side 102, the textured substrate 100 may beturned over and passed across the nozzle 18 of the slot coat header 14 asecond time such that the heated polymer is deposited on the other side,e.g., the second side 104 of the textured substrate 100, to form thepolymer particles 130, as described herein. It is to be understood thatthe polymer particles 130 may initially be formed on the second side 104(see FIG. 3B), after which the textured substrate 100 may be turned overand the polymer particles 120 may then be formed on the first side 102,as described herein. In other examples (not shown), a second slot coatercomprising a housing, a slot coat header, and a nozzle may be positionedopposite the slot coater 10 of FIGS. 9 and 10, such that heated polymermay be deposited on both sides 102, 104 of the textured substrate 100without turning over the textured substrate 100.

In another example, as shown in FIGS. 6 and 9, the area of the texturedsubstrate 400 that contacts the nozzle 18 of the slot coat header 14 maycomprise the low-density zones 426, which extend outwardly from thesurface plane P₃ on both sides 402, 404 of the textured substrate 400.The heated polymer is substantially deposited onto the low-density zones426 when the textured substrate 400 is passed across the nozzle 18 ofthe slot coat header 14. In one example, with reference to FIGS. 5A and6, the low-density zones 426 may comprise the continuous region 208 andthe corresponding continuous portion 212. When the first side 202 of thetextured substrate 200 of FIG. 5A is facing the nozzle 18, the heatedpolymer is substantially deposited on the low-density continuous region208 to form polymer particles 420. When the second side 204 of thetextured substrate 200 of FIG. 5A is facing the nozzle 18, the heatedpolymer is substantially deposited on the low-density continuous portion212 to form polymer particles 430 (see also FIG. 10). In anotherexample, with reference to FIGS. 5B and 6, the low-density zones 426 maycomprise the discrete regions 206′ and the corresponding discreteportions 210′. When the first side 202′ of the textured substrate 200′of FIG. 5B is facing the nozzle 18, the heated polymer is substantiallydeposited on the low-density discrete regions 206′ to form polymerparticles 420. When the second side 204′ of the textured substrate 200′of FIG. 5B is facing the nozzle 18, the heated polymer is substantiallydeposited on the low-density discrete portions 210′ to form polymerparticles 430 (see also FIG. 10).

With reference to FIGS. 6, 9, and 10, in all examples, the heatedpolymer may be deposited on the low-density zones 426 such that thepolymer particles 420, 430 do not extend to the adjacent high-densityzones 424. For example, the heated polymer may be deposited on thelow-density zones 426 such that the polymer particles 420, 430 do notextend past the transition regions 414 positioned intermediate thelow-density zones 426 and the adjacent high-density zones 424. Inaddition, after the heated polymer is deposited on one side of thetextured substrate 400, e.g., the polymer particles 420 are formed onthe first side 402, the textured substrate 400 may be turned over andpassed across the nozzle 18 of the slot coat header 14 a second timesuch that the heated polymer is deposited on the other side, e.g., thesecond side 404 of the textured substrate 400, to form the polymerparticles 430, as described herein. It is to be understood that thepolymer particles 430 may initially be formed on the second side 404,after which the textured substrate 400 may be turned over and thepolymer particles 420 may then be formed on the first side 402, asdescribed herein. As described herein, a second slot coater (not shown)may be used to deposit heated polymer on both sides 402, 404 of thetextured substrate 400 at substantially the same time.

In a further example, as shown in FIGS. 7, 8A, and 8B, the texturedsubstrate 600, 600′ may comprise a plurality of substantially continuousor semicontinuous, relatively high-density zones 624, 624′ and aplurality of substantially continuous or semicontinuous, relativelylow-density zones 626, 626′. With reference to FIGS. 8A and 9, when thefirst side 602 of the textured substrate 600 is facing the nozzle 18,the area of the textured substrate 600 that contacts the nozzle 18comprises the low-density zones 626, such that the heated polymer issubstantially deposited onto the low-density zones 626 when the texturedsubstrate 600 is passed across the nozzle 18 of the slot coat header 14.The heated polymer may be substantially deposited onto the low-densityzones 626 such that the polymer particles 620 do not extend to theadjacent high-density zones 624. Because the heated polymer is depositedbased on contact of the textured substrate 600 with the nozzle 18 of theslot coat header 14 and solidifies quickly, it is believed that littleor no heated polymer is deposited on or flows to other areas of thetextured substrate 600 that do not contact the nozzle 20. For example,the heated polymer may be deposited on the low-density zones 626 suchthat the polymer particles 620 do not extend past the transition regions614 positioned intermediate the low-density zones 626 and the adjacenthigh-density zones 624. In some particular examples, as describedherein, the low-density zones 626 may comprise an outer section 616 andsidewall sections 618 extending outwardly from the adjacent high-densityzones 624 and from the surface plane P₄ to the outer section 616 of therespective low-density zone 626. In some instances, the heated polymermay be deposited only on the outer sections 616 of the low-density zones626. As shown in FIG. 8A, the outer section 616 of the low-density zones626 may be dome-shaped, and the heated polymer may be substantiallydeposited on an outermost part of the dome-shaped outer section 616,i.e., the area of the outer portion 616 that is generally co-planar withthe surface plane P₄ of the textured substrate 600.

With reference to FIGS. 8A and 10, when the second side 604 of thetextured substrate 600 is facing the nozzle, the area of the texturedsubstrate 600 that contacts the nozzle 18 comprises the high-densityzones 624, such that the heated polymer is substantially deposited ontothe high-density zones 624 when the textured substrate 600 is passedacross the nozzle 18 of the slot coat header 14. Polymer particles 630are formed on the high-density zones 624 and do not extend to theadjacent low-density zones 626. Because the heated polymer is depositedbased on contact of the textured substrate 600 with the nozzle 18 andsolidifies quickly, it is believed that little or no heated polymer isdeposited on or flows to other areas of the textured substrate 600 thatdo not contact the nozzle 18. For example, the heated polymer may bedeposited on the high-density zones 624 such that the polymer particles630 do not extend past the transition regions 614 positionedintermediate the high-density zones 624 and the adjacent low-densityzones 626. In some instances, the high-density zones 624 may define asubstantially planar area 648 on the second side 604, and the heatedpolymer may be substantially deposited onto the substantially planararea 648 of the high-density zones 624.

With reference to FIGS. 8B and 9, the area that contacts the nozzle 18of the slot coat header 14 may comprise the low-density zones 626′,which extend outwardly from the surface plane P_(4′) on both sides 602′,604′ of the textured substrate 600′. The heated polymer is substantiallydeposited onto the low-density zones 626′ when the textured substrate600′ is passed across the nozzle 18 of the slot coat header 14. When thefirst side 602′ of the textured substrate 600′ is facing the nozzle 18,the heated polymer is substantially deposited on the low-density zones626′ to form polymer particles 620′. When the second side 604′ of thetextured substrate 600′ is facing the nozzle 18, the heated polymer issubstantially deposited on the low-density zones 626′ to form polymerparticles 630′. The heated polymer may be deposited on the low-densityzones 626′ such that the polymer particles 620′, 630′ do not extend tothe adjacent high-density zones 624′, as described herein. For example,the heated polymer may be deposited on the low-density zones 626′ suchthat the polymer particles 620′, 630′ do not extend past the transitionregions 614, 614′ positioned intermediate the low-density zones 626′ andthe adjacent high-density zones 624′.

In addition, with reference to FIGS. 8A, 8B, 9, and 10, after the heatedpolymer is deposited on one side of the textured substrate 600, 600′,e.g., the polymer particles 620, 620′ are formed on the first side 602,602′, the textured substrate 600, 600′ may be turned over and passedacross the nozzle 18 of the slot coat header 14 a second time such thatthe heated polymer is deposited on the other side, e.g., the second side604, 604′ of the textured substrate 600, 600′, to form the polymerparticles 630, 630′, as described herein. It is to be understood thatthe polymer particles 630, 630′ may initially be formed on the secondside 604, 604′, after which the textured substrate 600, 600′ may beturned over and the polymer particles 620, 620′ may then be formed onthe first side 602, 602′, as described herein. As described herein, asecond slot coater (not shown) may be used to deposit heated polymer onboth sides 602, 602′, 604, 604′ of the textured substrate 600, 600′ atsubstantially the same time.

With reference to FIGS. 9 and 10, in all examples described herein, oneor more segments of the nozzle 18 of the slot coat header 14 may beblocked such that the heated polymer is deposited only on one or moresections of the textured substrate 100 to form one or more patterns ordesigns. For example, a central segment of the nozzle 18 may be blockedso that the heated polymer is deposited only along one or both edges ofthe textured substrate 100 in the machine direction (MD). In anotherexample, several discrete segments of the nozzle 18 may be blocked sothat the heated polymer is deposited in MD stripes on the texturedsubstrate 100. In other examples, solenoids (not shown) on the slot coatheader 14 may be pulsed to achieve a pulsed flow rate of the heatedpolymer, as is known in the art.

In all examples described herein, each polymer particle may comprise amacro-shape or configuration and a micro-shape or configuration, inwhich the macro-shape/configuration refers to characteristics of thepolymer particle as a whole and the micro-shape/configurations refers tocharacteristics of the polymer particle with respect to individualfibers or groups of fibers of the textured substrate on which thepolymer particle is formed.

FIGS. 11A-11E are plan views of portions of a first side 702 of anexemplary one-ply textured substrate 700 according to the presentdisclosure. The textured substrate 700 comprises discrete regions 706and a continuous region 708, in which the discrete regions 706 comprisepolymer particles with a macro-shape comprising generally one of a discshape 720A, a full ring 720B, 720E, a partial ring 720C, or a disc shapewith an overhang 720D. FIG. 12A is a cross-sectional view taken alongthe line 12-12 of one of the polymer particles 720A depicted in FIG.11A, and FIG. 12B is a cross-sectional view, similar to FIG. 12A, of anadditional exemplary polymer particle 720A′. FIG. 13 is across-sectional view taken along line 13-13 of one of the polymerparticles 720D depicted in FIG. 11D. While the cross-sectional shape ofthe discrete region 706 depicted in FIGS. 12A, 12B, and 13 most closelycorresponds to the discrete region 106 depicted in FIG. 2A, the discreteregions 706 of FIGS. 11A-11E may also substantially correspond, forexample, to the discrete regions 106, 106′, 206′ depicted in FIGS. 2B-2Dand 5B and may comprise low-density or high-density zones, as describedherein.

With reference to FIG. 11A-11E, each discrete region 706 may comprise anouter section 716 with a perimeter 717 along an outer edge of the outersection 716 and a sidewall section 718 extending outwardly from theadjacent continuous region 708 toward the outer section 716. Thedisc-shaped polymer particles 720A in FIG. 11A may substantiallycontinuously cover at least a portion of the outer section 716, and insome examples, the disc-shaped polymer particles 720A may extend up toor near the perimeter 717 of the outer section 716. The polymerparticles 720B, 720E with a full ring shape in FIGS. 11B and 11E mayextend substantially continuously along the perimeter 717 of the outersection 717, in which a central portion (not separately labeled) of theouter section 716 is not covered by the polymer particle 720B, 720E. Thepolymer particles 720C with the partial ring shape in FIG. 11C areformed along a segment of the perimeter 717 of the outer section 716 andmay comprise, for example, a horseshoe or crescent shape. The polymerparticles 720D with a disc shape comprising an overhang 723 maysubstantially continuously cover at least a portion of the outer section716, in which the overhang 723 may extend substantially horizontallyfrom the outer section 716 of the discrete region 706, as describedherein. As shown and as described herein, the macro-shape of the polymerparticles 720A-720E may be at least partially determined by a shape ofthe outer section 716 of the discrete region 706. A feed direction ofthe textured substrate 700 through a slot coater (not shown; see FIGS. 9and 10) is indicated by arrow C in FIGS. 12A, 12B, and 13.

With reference to FIGS. 11A, 12A, and 12B, at least a section of thepolymer particle 720A, 720A′ defines at least one raised edge 722A,722A′, 722B that is raised relative to a surface, i.e., the outersection 716, of the textured substrate 700 on which the polymer particle720A, 720A′ is formed (see also reference numbers 122, 122′, 422 inFIGS. 3A, 3C, 3D, and 6). With reference to FIG. 12A, in some examples,at least a portion of the polymer particle 720A, in cross-section, maycomprise a substantially uniform thickness T₁, and in some instances,may comprise the substantially uniform thickness T₁ across substantiallyan entirety of the polymer particle 720A from a leading edge 719 to atrailing edge 721 of the outer section 716 of the discrete region 706.The polymer particle 720A may define first and second raised edges 722A,722B. With reference to FIG. 12B, in other examples, the polymerparticle 720A′, in cross-section, may comprise a thickness that variesacross at least a portion of the polymer particle 720A′ and may defineone raised edge 722A′. For example, one portion of the polymer particle720A′ may comprise a first thickness T_(1′) and another portion of thepolymer particle 720A′ may comprise a second thickness T_(2′), in whichT_(2′) is less than T_(1′). In some instances, the segment of thepolymer particle 720A′ nearest the leading edge 719 of the outer section716 of the discrete region 706, e.g., the raised edge 722A′, maycomprise the first thickness T_(1′) and the segment of the polymerparticle 720A′ that is located toward the trailing edge 721 of the outersection 716 of the discrete region 706 may comprise the second thicknessT_(2′). In some particular examples, as shown in FIG. 12B, the polymerparticle 720A′ with a varying thickness may comprise generally ateardrop or foil shape that tapers substantially continuously from theleading edge 719 of the outer section 716 of the discrete region 706toward the trailing edge 721. The polymer particles comprising a fullring 720B, 720E or a partial ring 720C may comprise any of thecross-sectional profiles depicted in FIGS. 12A and 12B.

With reference to FIGS. 11D and 13, one portion of the polymer particle720D near the leading edge 719 of the outer section 716 of the discreteregion 706 defines a first raised edge 722A relative to the outersection 716 on which the polymer particle 720D is formed. The polymerparticle 720D further comprises an overhang 723 extending from thetrailing edge 721 of the outer section 716 of the outer section 716 ofthe discrete region 706. It is believed that at least a portion of theoverhang 723 may extend substantially parallel to a surface plane P₅ ofthe textured substrate 700, in which the surface plane P₅ may be atleast partially defined by the continuous region 708. While the overhang723 may extend above the adjacent continuous region 708, it is believedthat the polymer particle 720D does not extend to the continuous region708, i.e., the polymer particle 720D is not deposited on and does notflow into the continuous region 708 during formation, as describedherein. When the textured substrate 700 is fed through a slot coater(see FIGS. 9 and 10), the heated polymer deposited onto the discreteregion 706 solidifies quickly and may form the overhang 723 based on thecharacteristics of the polymer and/or the operating parameters of theslot coater, as described herein. Further, because the heated polymer isdeposited based on contact of the textured substrate 700 with the nozzleof the slot coat header (see FIG. 9), it is believed that little or noheated polymer is deposited on or flows to other areas of the texturedsubstrate 700 that do not contact the nozzle. For example, it isbelieved that a portion (not shown) of the overhang 723 may extend to,contact, and/or coat a section of the sidewall 718 of the discreteregion 706 that is located beneath the overhang 723 but withoutextending to or contacting the adjacent continuous region 708, i.e.,without extending past the transition regions 714. As shown in FIG. 13,in some examples, it is believed at least a portion of the polymerparticle 720D, in cross-section, may comprise a substantially uniformthickness (not labeled; see FIG. 12A), and in some instances, maycomprise the substantially uniform thickness across substantially anentirety of the polymer particle 720D from the leading edge 719 to thetrailing edge 721 of the outer section 716 of the discrete region 706.In other examples (not shown; see FIG. 12B), it is believed that thepolymer particle 720D, in cross-section, may comprise a thickness thatvaries across at least a portion of the polymer particle 720D.

FIG. 14 is a plan view of a portion of a second side 704 of a texturedsubstrate 700 comprising discrete portions 710 and a continuous portion712, in which the continuous portion 712 comprises polymer particles730. FIG. 15A is a cross-sectional view taken along the line 15-15 ofone of the polymer particles 730 depicted in FIG. 14, and FIG. 15B is across-sectional view, similar to FIG. 15A, of an additional exemplarypolymer particle 730′. While the cross-sectional shape of the continuousportion 712 depicted in FIGS. 15A and 15B most closely corresponds tothe continuous portion 112′ shown in FIG. 2B, the continuous portion 712of FIG. 14 may also substantially correspond, for example, to thecontinuous portions 112, 212 depicted in FIGS. 2A and 5A and maycomprise low-density or high-density zones, as described herein. A feeddirection of the textured substrate 700 through a slot coater (notshown; see FIGS. 9 and 10) is indicated by arrow C in FIGS. 15A and 15B.

Because the continuous portion 712 may generally comprise asemicontinuous or continuous grid or network, the macro-shape of thepolymer particles 730, 730′ formed on the continuous portion 712 mayrange from a shape that approximately follows the semicontinuous orcontinuous network, i.e., semicontinuous or continuous strips, to anamorphous shape. The macro-shape of the polymer particles 730, 730′ mayalso be at least partially determined by an orientation of the texturedsubstrate 700 with respect to the nozzle of the slot coater (not shown;see FIGS. 9 and 10).

As shown in FIGS. 15A and 15B, at least a section of each polymerparticle 730, 730′ defines at least one raised edge 732A, 732A′, 732B,which is raised relative to a surface, i.e., the continuous portion 712,of the textured substrate 700 on which the polymer particle 730, 730′ isformed (see also reference numbers 132, 132′, 432 in FIGS. 3B-3D and 6).With reference to FIG. 15A, in some examples, at least a portion of thepolymer particle 730, in cross-section, may comprise a substantiallyuniform thickness T₁, in some instances, may comprise the substantiallyuniform thickness T₁ across substantially an entirety of the polymerparticle 730 from a leading edge 713 to a trailing edge 715 of thecontinuous portion 712. The polymer particle 730 may define first andsecond raised edges 732A, 732B. With reference to FIG. 15B, in otherexamples, the polymer particle 730′, in cross-section, may comprise athickness that varies across at least a portion of the polymer particle730′ and may define one raised edge 732A′. For example, one portion ofthe polymer particle 730′ may comprise a first thickness T_(1′),andanother portion of the polymer particle 730′ may comprise a secondthickness T_(2′), in which T_(2′) is less than T_(1′). In someinstances, the segment of the polymer particle 730′ nearest the leadingedge 713 of the continuous portion 712, e.g., the raised edge 732A′,comprises the first thickness T_(1′),and the segment of the polymerparticle 730′ that is located toward the trailing edge 715 of thecontinuous portion 712 may comprise the second thickness T_(2′). In someparticular examples, as shown in FIG. 15B, the polymer particle 730′with a varying thickness may comprise generally a teardrop or foil shape‘that tapers substantially continuously from the leading edge 713 of thecontinuous portion 712 toward the trailing edge 715. Although not shown,it is believed that the polymer particles 730 formed on the continuousportion 712 may also comprise a structure similar to the polymerparticle 720D comprising an overhang 723, as depicted in FIG. 13, inwhich the overhang would extend from the trailing edge 715 of thecontinuous portion 712 substantially parallel to a surface plane (notshown; see FIG. 2B) of the textured substrate 700.

Although not discussed in detail, the polymer particles 620, 620′, 630,630′ formed on the textured substrate 600, 600′ of FIGS. 7, 8A, and 8Bcomprising a plurality of substantially continuous or semicontinuous,relatively high-density zones 624, 624′ and a plurality of substantiallycontinuous or semicontinuous, relatively low-density zones 626, 626′ maysubstantially correspond to any of the examples shown in FIGS. 11A-11E,12A, 12B, 13, 14, 15A, and 15B. The macro-shape of the polymer particles620, 620′, 630, 630′ may be at least partially defined by a shape of thehigh-density and/or low-density zones 624, 624′, 626, 626′ on which thepolymer particles 620, 620′, 630, 630′ are formed. For example, polymerparticles 620, 620′ formed on the low-density zones 626, 626′ of thefirst side 602, 602′ of the textured substrate 600 may comprisecontinuous or semicontinuous strips that substantially conform to thesubstantially continuous or semicontinuous ridges formed by thelow-density zones 626, 626′. Likewise, the polymer particles 630, 630′formed on the second side 604, 604′ of the textured substrate, which mayinclude the polymer particles 630 formed on the substantially planarareas 648 of the high-density zones 624 and the polymer particles 630′formed on the low-density zones 626′, may comprise continuous orsemicontinuous strips that substantially conform to the substantiallycontinuous or semicontinuous ridges formed by the high-density zones 624or the low-density zones 626′. In addition, the macro-shape of thepolymer particles 620, 620′, 630, 630′ may be at least partiallydetermined by an orientation of the textured substrate 600, 600′ withrespect to the nozzle of the slot coater (not shown; see FIGS. 9 and10).

In all examples described herein, the micro-shape or configuration ofthe polymer particles 720A-720C, 720A′, 730, 730′ of FIGS. 11A-11E, 12A,12B, 13, 14, 15A, 15B may comprise one or more of fiber-coated, in whichthe polymer particles 720A-720C, 720A′, 730, 730′ coat at least aportion of the individual fibers comprising the textured substrate 700,or fragmented, in which the polymer particles 720A-720C, 720A′, 730,730′ span between individual fibers. The extent of fiber-coating and/orfragmentation may be dependent, at least in part, on whether the polymerparticles 720A-720C, 720A′, 730, 730′ are formed on high-density zonesor low-density zones. For example, it is believed that fiber-coatingoccurs in both high- and low-density zones, but in high-density zoneswhere the fibers are densified, a greater proportion of the polymerparticles 720A-720C, 720A′, 730, 730′ may comprise a fragmentedmicro-shape due to the closer proximity of the fibers. Low-density zonesmay generally comprise a greater proportion of polymer particles720A-720C, 720A′, 730, 730′ comprising a fiber-coated micro-shape due tothe greater distance between the fibers. The polymer particles asdescribed herein may comprise, for example, polyethylene, polypropylene,polylactic acid, ethylene-vinyl acetate, and copolymers thereof. Inother examples, the polymer particles may comprise biodegradablepolymers such as polycaprolactone, thermoplastic starch,poly(3-hydroxybutyrate-co-3-hydroxyvalerate), as well as naturalmaterials such as one or more waxes. Examples of suitable polymers mayinclude, but are not limited to, Metocene® MF650Y (LyondellBasell) andLicocene® 4201 and 1302 (Clariant). In some instances, the heatedpolymer used to form the polymer particles may comprise one or moreadditional inorganic or organic materials. These additional materialsmay comprise one or more additives such as dye or other colorants,wetting agents, fillers, fluorescents, polymer toughening agents,perfumes, surfactants, or oils.

In all examples described herein, the characteristics of the polymerparticles, in particular the micro- and macro-shape, may be controlled,at least in part, by a combination of the properties of the polymer(s)and/or polymer solution(s) selected for forming the polymer particlesand/or the conditions under which the heated polymer is deposited ontothe textured substrate. For example, a polymer having a specifiedrheology or rheological profile, surface energy, viscosity,crystallization temperature, and/or solidification rate may be selectedto achieve polymer particles having a desired set of characteristics. Inaddition, a polymer flow rate, a temperature of the heated polymer andslot coater components, a contact surface area (e.g., the surface areaof the textured substrate onto which the heated polymer is deposited), afeed speed of the textured substrate (e.g., a speed at which thetextured substrate is passed across the nozzle of the slot coat header),a degree of engagement between the textured substrate and the nozzle ofthe slot coat header, and/or an amount of cooling applied to thetextured substrate following formation of the polymer particles may beadjusted to achieve polymer particles having the desired set ofcharacteristics.

In particular, a ratio of the polymer flow rate to the contact surfacearea of the textured substrate may be controlled to achieve polymerparticles of a specific shape and thickness. A higher polymer flow rateand/or smaller contact surface area generally results in greater polymercoverage and thickness. For example, with reference to FIGS. 11A-11C and11E, the disc-shaped polymer particles 720A that cover substantially anentirety of the outer section 716 of the discrete region 706 willgenerally require a higher polymer flow rate than the polymer flow raterequired to generate the polymer particles having a full ring shape720B, 720E or a partial ring shape 720C. In addition, a relatively largetextured substrate contact surface area will generally result in polymerparticles that cover less of the contact surface area, e.g., the polymerparticles having the full ring shape 720B, 720E or the partial ringshape 720C (as compared to the formation of the disc-shaped polymerparticles 720A on a relatively small contact surface area, assuming aconstant polymer flow rate).

In particular, a combination of one or more of the ratio of the polymerflow rate to the contact surface area of the textured substrate, thefeed speed of the textured substrate, and/or the degree of engagementbetween the textured substrate and the nozzle of the slot coat headermay be used to control the cross-sectional thickness and shape of thepolymer particles. With reference to FIGS. 12A and 15A, a polymerparticle 720A, 730 comprising a substantially uniform thickness acrosssubstantially an entirety of the polymer particle 720A, 730 may beformed by selecting a ratio and a feed speed that cause a substantiallyuniform amount of the heated polymer to be deposited across the entiretyof the contact surface area, e.g., from the leading edge 713, 719 to thetrailing edge 715, 721 of respective outer section 716 of the discreteregion 706 or continuous portion 712. In addition, or alternatively, alarger degree of engagement between the textured substrate and thenozzle may be used to ensure that a substantially consistent amount ofheated polymer is deposited across the entirety of the contact surfacearea.

With reference to FIGS. 12B and 15B, a polymer particle 720A′, 730′comprising a cross-sectional thickness that that varies across at leasta portion of the polymer particle 720A′, 730′ may also be formed byselecting a ratio, a feed speed, and/or a degree of engagement thatcause a greater amount of the heated polymer to be deposited at or nearthe leading edge 713, 719 of the outer section 716 of the discreteregion 706 or the continuous portion 712, as compared to an amount ofheated polymer deposited toward the trailing edge 715, 721. For example,the polymer flow rate may be selected such that excess polymer pools atthe opening of the nozzle when the nozzle is not in contact with thetextured substrate. The hot melt extruder (see FIG. 9) continues tosupply the heated polymer at a constant rate, and the excess polymer isthen deposited at the leading edge 713, 719 when the nozzle encountersthe next discrete region 706 or continuous portion 712. In addition, oralternatively, polymer particles having a varying cross-sectionalthickness may be achieved based on the degree of engagement between thetextured substrate and the nozzle. For example, a smaller degree ofengagement means that the excess polymer may be deposited at the leadingedge 713, 719, after which the amount of polymer deposited on theremainder of the contact surface may be substantially uniform.

With reference to FIGS. 11D and 13, a polymer particle 720D comprisingan overhang 723 may be achieved by selecting a ratio, a feed speed,and/or a degree of engagement that causes an excess amount of polymer tobuild up during deposition, which is then pushed or carried past thetrailing edge 721 in a direction opposite to the arrow C andsubstantially parallel to the surface plane P₅. For example, it isbelieved that a high polymer flow rate, slower feed speed, and/orgreater degree of engagement causes an excess of polymer to be depositedas the nozzle moves from the leading edge 719 of the outer section 716of the discrete region 706 to the trailing edge 721. When the nozzlereaches the trailing edge 721 and the open space above the continuousregion, it is believed that a portion of the excess polymer disengagesfrom the nozzle to form the overhang 723.

The characteristics of the polymer particles may further be controlled,at least in part, by one or more properties of the polymer(s) and/orpolymer solution(s) used to form the polymer particles. For example, apolymer or polymer solution with a higher surface energy and/orviscosity may form polymer particles that cover less of the contactsurface area (e.g., the polymer particles with a full ring 720B, 720E orpartial ring shape 720C in FIGS. 11B, 11C, and 11E) and/or may formpolymer particles with a cross-sectional thickness that varies across atleast a portion of the polymer particle, as shown in FIGS. 12B and 15B.A polymer or polymer solution with a lower surface energy and/orviscosity may be used to form polymer particles that cover a greateramount of the contact surface area (e.g., the disc-shaped polymerparticles 720A in FIG. 11A) and/or may form polymer particles with asubstantially uniform cross-sectional thickness, as shown in FIGS. 12Aand 15A.

The example depicted in FIGS. 11D and 13 with disc-shaped polymerparticles 720D comprising an overhang 723 may be created by controllinga variety of factors, including the ratio of the polymer flow rate tothe contact surface area of the textured substrate 700, the feed speed,and a cooling rate of the heated polymer after the polymer is depositedon the textured substrate 700. For example, with reference to FIG. 13,it is believed that the overhang 723 may be formed by selecting a ratiothat causes a substantial amount of the heated polymer to be depositedacross the entirety of the contact surface, e.g., from the leading edge719 to the trailing edge 721 of the outer section 716 of the discreteregion 706, and selecting a feed speed that causes at least a portion ofthe heated polymer to be pushed or carried past the trailing edge 721 ina direction opposite to the arrow C and substantially parallel to thesurface plane P₅, as described above. Immediately following depositionof the polymer particles 720D, the textured substrate 700 may be cooled(e.g., by application of a cooling airflow by a fan or other coolingdevice (not shown)) such that the polymer quickly solidifies and hardensin place to retain the overhang 723 of polymer material that does notextend to the continuous region 708.

Multi-Ply Fibrous Structures

As shown in FIGS. 16A-16C, textured substrates according to the presentdisclosure may form one or more plies of a multi-ply fibrous structure901, 901′, 901″. Each fibrous structure 901, 901′, 901″ may comprise arespective first ply comprising a first substrate 800, 800′, 800″ and arespective second ply that comprises a second substrate 900, 900′, 900″.The second substrate 900, 900′, 900″ may be joined to the firstsubstrate 800, 800′, 800″ using, for example, a marrying roll to adherethe two substrates 800, 800′, 800″, 900, 901′, 901″ together, asdescribed herein, or any other suitable method known in the art. Anoutermost ply may define first and second outer surfaces 901-A, 901-A′,901-A″, 901-B, 901-B′. 901-B″ of each respective fibrous structure 901,901′, 901″.

Although the depictions of the first and second substrates 800, 800′,800″, 900, 900′, 900″ of FIGS. 16A-16C may most closely correspond tothe structure of the textured substrates 100, 100′ of FIGS. 2A and 2B,the first and second substrates 800, 800′, 800″, 900, 900′, 900″ mayrepresent any of the textured substrates described herein. In someexamples, one of the first or second substrates 800, 800′, 800″, 900,900′, 900″ may represent a conventional substrate that is not coatedwith polymer particles and in some instances, may lack texturing (i.e.,the conventional substrate may comprise a substantially planar sheetthat lacks discrete and continuous regions/portions as describedherein). The polymer particles 820, 820′, 820″, 920, 920′, 920″, 830,830′, 830″, 930, 930′, 930″ depicted in FIGS. 16A-16C may likewiserepresent any of the polymer particles described herein.

In addition, although the multi-ply fibrous structures 901, 901′, 901″depicted in FIGS. 16A-16C comprise two plies, it is to be understoodthat the multi-ply fibrous structures 901, 901′, 901″ according to thepresent disclosure may comprise three plies, four plies, five plies,etc., and may comprise at least one textured substrate according to thepresent disclosure that is joined to one or more additional texturedsubstrates according to the present disclosure and/or to one or moreconventional substrates in any order and/or orientation, as describedherein. In some examples, at least one ply may comprise a texturedsubstrate according to the present disclosure and at least one other plymay comprise a conventional substrate. In other examples, all plies maycomprise a textured substrate according to the present disclosure. Asnoted above, a fibrous structure of the present invention may alsocomprise a single-ply or textured substrate, such as any one of thetextured substrates described above.

With reference to FIGS. 16A-16C, a first side 802, 802′, 802″ of eachfirst substrate 800, 800′, 800″ (also referred to herein as a firsttextured substrate) may comprise first discrete regions 806, 806′, 806″and a first continuous region 808, 808′, 808″ extending between thefirst discrete regions 806, 806′, 806″. A second side 804, 804′, 804″ ofeach first textured substrate 800, 800′, 800″ may comprise firstdiscrete portions 810, 801, 810″ corresponding to the first discreteregions 806, 806′, 806″ and a first continuous portion 812, 812′, 812″corresponding to the first continuous region 808, 808′, 808″. The firsttextured substrates 800, 800′, 800″ may each comprise first polymerparticles deposited on at least one of the first side 802, 802′, 802″ orthe second side 804, 804′, 804″. In some examples, each of the firsttextured substrates 800, 800′, 800″ of FIGS. 16A-16C may comprisepolymer particles 820, 820′, 820″ deposited on the first side 802, 802′,802″ on the first discrete regions 806, 806′, 806″. In other examples,each of the first textured substrates 800, 800′, 800″ may comprisepolymer particles 830, 830′, 830″ deposited on the second side 804,804′, 804″ on the first continuous portion 812, 812′, 812″. In furtherexamples, each of the first textured substrates 800, 800′, 800″ maycomprise polymer particles 820, 820′, 820″, 830, 830′, 830″ deposited onboth of the first and second sides 802, 802′, 802″, 804, 804′, 804″. Atleast a section of each of the first polymer particles 820, 820′, 820″,830, 830′, 830″ may define a raised edge, as described herein (notlabeled; see FIGS. 12A, 12B, 13, 15A, and 15B).

In some particular instances, when the polymer particles 820, 820′, 820″are deposited on the first side 802, 802′, 802″, the polymer particles820, 820′, 820″ are deposited only on the first discrete regions 806,806′, 806″. In other particular instances, the first discrete regions806, 806′, 806″ may each comprise an outer section and sidewall sections(not labeled; see FIGS. 2A and 2B) extending outwardly from the adjacentfirst continuous region 808, 808′, 808″ to the outer section of therespective first discrete region 806, 806′, 806″. When the polymerparticles 820, 820′, 820″ are deposited on the first side 802, 802′,802″, the polymer particles 820, 820′, 820″ may be substantiallydeposited on the outer sections of the first discrete regions 806, 806′,806″ and may not extend to the adjacent first continuous region 808,808′, 808″, as described herein. In some examples, the polymer particles820, 820′, 820″ may be deposited only on the outer sections of the firstdiscrete regions 806, 806′, 806″.

In further particular instances, when the polymer particles 830, 830′,830″ are deposited on the second side 804, 804′, 804″, the polymerparticles 830, 830′, 830″ may be substantially deposited on the firstcontinuous portion 812, 812′, 812″ and may not extend to the adjacentfirst discrete portions 810, 801, 810″, as described herein. In someexamples, when the polymer particles 830, 830′, 830″ are deposited onthe second side 804, 804′, 804″, the polymer particles 830, 830′, 830″may be deposited only on the first continuous portion 812, 812′, 812″.

In some examples, a plurality of the first discrete regions 806, 806′,806″ and the corresponding first discrete portions 810, 801, 810″ maycomprise high-density zones and the first continuous region 808, 808′,808″ and the corresponding first continuous portion 812, 812′, 812″ maycomprise low-density zones, as described herein (not labeled; see FIGS.2A and 2C-2E). In other examples, a plurality of the first discreteregions 806, 806′, 806″ and the corresponding first discrete portions810, 801, 810″ may comprise low-density zones and the first continuousregion 808, 808′, 808″ and the corresponding first continuous portion812, 812′, 812″ may comprise high-density zones, as described herein(not labeled; see FIG. 2B). The polymer particles 820, 820′, 820″, 830,830′, 830″ may be substantially deposited on the high-density zones,low-density zones, or both (see FIGS. 3A-3D).

In further examples, one of (i) the first discrete regions 806, 806′,806″ and the corresponding first discrete portions 810, 810′, 810″ or(ii) the first continuous region 808, 808′, 808″ and the correspondingfirst continuous portion 812, 812′, 812″ may comprise high-densityzones, and the other of (i) the first discrete regions 806, 806′, 806″and the corresponding first discrete portions 810, 810′, 810″ or (ii)the first continuous region 808, 808′, 808″ and the corresponding firstcontinuous portion 812, 812′, 812″ may comprise low-density zones, inwhich the polymer particles 820, 820′, 820″, 830, 830′, 830″ may besubstantially deposited on the low-density zones on one or both of thefirst side 802, 802′, 802″ or the second side 804, 804′, 804″ (see FIGS.5A, 5B, and 6). In some particular examples, the polymer particles 820,820′, 820″, 830, 830′, 830″ may be deposited only on the low-densityzones (see FIG. 6)

With continued reference to FIG. 16A-16C, each of the second substrates900, 900′, 900″ may comprise a third side 902, 902′, 902″ and a fourthside 904, 904′, 904″. In some examples, the second substrates 900, 900′,900″ may comprise a conventional, uncoated substrate without polymerparticles. In some instances, the second substrates 900, 900′, 900″ maycomprise no texturing, i.e., the second substrates 900, 900′, 900″ maycomprise a substantially planar sheet. In other instances, the secondsubstrates 900, 900′, 900″ may comprise texturing (also referred toherein as a second textured substrate), in which the third side 902,902′, 902″ of each second textured substrate 900, 900′, 900″ maycomprise second discrete regions 906, 906′, 906″ and a second continuousregion 908, 908′, 908″ extending between the second discrete regions906, 906′, 906″ and the fourth side 904, 904′, 904″ of each secondtextured substrate 900, 900′, 900″ may comprise second discrete portions910, 901, 910″ corresponding to the second discrete regions 906, 906′,906″ and a second continuous portion 912, 912′, 912″ corresponding tothe second continuous region 908, 908′, 908″.

Each of the second textured substrates 900, 900′, 900″ may comprisesecond polymer particles deposited on at least one of the third side902, 902′, 902″ or the fourth side 904, 904′, 904″. In some examples,each of the second textured substrates 900, 900′, 900″ may comprisepolymer particles 920, 920′, 920″ deposited on the third side 902, 902′,902″ on the second discrete regions 906, 906′, 906″. In other examples,each of the second textured substrates 900, 900′, 900″ may comprisepolymer particles 930, 930′, 930″ deposited on the fourth side 904,904′, 904″ on the second continuous portion 912, 912′, 912″. In furtherexamples, each of the second textured substrates 900, 900′, 900″ maycomprise polymer particles 920, 920′, 920″, 930, 930′, 930″ deposited onboth of the third and fourth sides 902, 902′, 902″, 904, 904′, 904″. Atleast a section of each of the second polymer particles 920, 920′, 920″,930, 930′, 930″ may define a raised edge, as described herein (notlabeled; see FIGS. 12A, 12B, 13, 15A, and 15B).

In some particular instances, when the polymer particles 920, 920′, 920″are deposited on the third side 902, 902′, 902″, the polymer particles920, 920′, 920″ may be deposited only on the second discrete regions906, 906′, 906″. In other particular instances, the second discreteregions 906, 906′, 906″ may each comprise an outer section and sidewallsections (not labeled; see FIGS. 2A and 2B) extending outwardly from theadjacent second continuous region 908, 908′, 908″ to the outer sectionof the respective second discrete region 906, 906′, 906″. When thepolymer particles 920, 920′, 920″ are deposited on the third side 902,902′, 902″, the polymer particles 920, 920′, 920″ may be substantiallydeposited on the outer sections of the second discrete regions 906,906′, 906″ and may not extend to the adjacent second continuous region908, 908′, 908″, as described herein. In some particular examples, thepolymer particles 920, 920′, 920″ may be deposited only on the outersections of the first discrete regions 906, 906′, 906″. In furtherparticular instances, when the polymer particles 930, 930′, 930″ aredeposited on the fourth side 904, 904′, 904″, the polymer particles 930,930′, 930″ may be substantially deposited on the second continuousportion 912, 912′, 912″ and may not extend to the adjacent seconddiscrete portions 910, 901, 910″, as described herein. In someparticular examples, when the polymer particles 930, 930′, 930″ aredeposited on the fourth side 904, 904′, 904″, the polymer particles 930,930′, 930″ may be deposited only on the second continuous portion 912,912′, 912″.

In some examples, a plurality of the second discrete regions 906, 906′,906″ and the corresponding second discrete portions 910, 901, 910″ maycomprise high-density zones and the second continuous region 908, 908′,908″ and the corresponding second continuous portion 912, 912′, 912″ maycomprise low-density zones, as described herein (not labeled; see FIGS.2A and 2C-2E). In other examples, a plurality of the second discreteregions 906, 906′, 906″ and the corresponding second discrete portions910, 901, 910″ may comprise low-density zones and the second continuousregion 908, 908′, 908″ and the corresponding second continuous portion912, 912′, 912″ may comprise high-density zones, as described herein(not labeled; see FIG. 2B). The polymer particles 920, 920′, 920″, 930,930′, 930″ may be substantially deposited on the high-density zones,low-density zones, or both (see FIGS. 3A-3D).

In further examples, one of (i) the second discrete regions 906, 906′,906″ and the corresponding second discrete portions 910, 910′, 910″ or(ii) the second continuous region 908, 908′, 908″ and the correspondingsecond continuous portion 912, 912′, 912″ may comprise high-densityzones, and the other of (i) the second discrete regions 906, 906′, 906″and the corresponding second discrete portions 910, 910′, 910″ or (ii)the second continuous region 908, 908′, 908″ and the correspondingsecond continuous portion 912, 912′, 912″ may comprise high-densityzones may comprise low-density zones, in which the polymer particles920, 920′, 920″, 930, 930′, 930″ may be substantially deposited on thelow-density zones on one or both of the first side 902, 902′, 902″ orthe second side 904, 904′, 904″ (see FIGS. 5A, 5B, and 6). In someparticular examples, the polymer particles 920, 920′, 920″, 930, 930′,930″ may be deposited only on the low-density zones (see FIG. 6).

In yet further examples, the fibrous structures 900, 900′, 900″ maycomprise a multi-ply structure in which at least one ply comprises atextured substrate having a plurality of substantially continuous orsemicontinuous, relatively high-density zones and a plurality ofsubstantially continuous or semicontinuous, relatively low-densityzones, as described herein (see FIGS. 7, 8A, and 8B). The texturedsubstrate may comprise polymer particles formed on at least one of afirst side or a second side of the textured substrate, as describedherein. The polymer particles may be substantially deposited on an areaof the textured substrate that extends outwardly from a first surfaceplane of the textured substrate, and at least a section of each of thepolymer particles may define a raised edge, as described herein. Thepolymer particles may be substantially deposited on the high-densityzones, low-density zones, or both (see FIGS. 8A and 8B).

With reference to FIGS. 16A-16C, in some examples, when the polymerparticles 820, 820′, 820″ are deposited on the first side 802, 802′,802″ of the first textured substrate 800, 800′, 800″ and the first side802, 802′, 802″ of the first textured substrate 800, 800′, 800″ ispositioned directly adjacent to the second substrate 900, 900′, 900″,the first and second substrates 800, 800′, 800″, 900, 900′, 900″ may beoriented such that the polymer particles 820, 820′, 820″ are locatedwithin the fibrous structure 901, 901′, 901″. In other examples, whenthe polymer particles 820, 820′, 820″ are deposited on the first side802, 802′, 802″ of the first textured substrate 800, 800′, 800″ and thesecond side 804, 804′, 804″ of the first textured substrate 800, 800′,800″ is positioned directly adjacent to the second substrate 900, 900′,900″, the first and second substrates 800, 800′, 800″, 900, 900′, 900″may be oriented such that the polymer particles 820, 820′, 820″ arelocated on an outer surface 901-A, 901-A′, 901-A″, 901-B, 901-B′, 901-B″of the fibrous structure 901, 901′, 901″. In further examples, when thepolymer particles 830, 830′, 830″ are deposited on the second side 804,804′, 804″ of the first textured substrate 800, 800′, 800″ and thesecond side 804, 804′, 804″ of the first textured substrate 800, 800′,800″ is positioned directly adjacent to the second substrate 900, 900′,900″, the first and second substrates 800, 800′, 800″, 900, 900′, 900″may be oriented such that the polymer particles 830, 830′, 830″ arelocated within the fibrous structure 901, 901′, 901″. In yet furtherexamples, when the polymer particles 830, 830′, 830″ are deposited onthe second side 804, 804′, 804″of the first textured substrate 800,800′, 800″ and the first side 802, 802′, 802″ of the first texturedsubstrate 800, 800′, 800″ is positioned directly adjacent to the secondsubstrate 900, 900′, 900″, the first and second substrates 800, 800′,800″, 900, 900′, 900″ may be oriented such that the polymer particles830, 830′, 830″ are located on an outer surface 901-A, 901-A′, 901-A″,901-B, 901-B′. 901-B″ of the fibrous structure 901, 901′, 901″.

With continued reference to FIGS. 16A-16B, in some examples, when thepolymer particles 920, 920′, 920″ are deposited on the third side 902,902′, 902″ of the second substrate 900, 900′, 900″ and the third side902, 902′, 902″ of the second substrate 900, 900′, 900″ is positioneddirectly adjacent to the first textured substrate 800, 800′, 800″, thefirst and second substrates 800, 800′, 800″, 900, 900′, 900″ may beoriented such that the polymer particles 920, 920′, 920″ are locatedwithin the fibrous structure 901, 901′, 901″. In other examples, whenthe polymer particles 920, 920′, 920″ are deposited on the third side902, 902′, 902″ of the second substrate 900, 900′, 900″ and the fourthside 904, 904′, 904″ of the second substrate 900, 900′, 900″ ispositioned directly adjacent to the first textured substrate 800, 800′,800″, the first and second substrates 800, 800′, 800″, 900, 900′, 900″may be oriented such that the polymer particles 920, 920′, 920″ arelocated on an outer surface 901-A, 901-A′, 901-A″, 901-B, 901-B′. 901-B″of the fibrous structure 901, 901′, 901″. In further examples, when thepolymer particles 930, 930′, 930″ are deposited on the fourth side 904,904′, 904″ of the second substrate 900, 900′, 900″ and the fourth side904, 904′, 904″ of the second substrate 900, 900′, 900″ is positioneddirectly adjacent to the first textured substrate 800, 800′, 800″, thefirst and second substrates 800, 800′, 800″, 900, 900′, 900″ may beoriented such that the polymer particles 930, 930′, 930″ are locatedwithin the fibrous structure 901, 901′, 901″. In yet further examples,when the polymer particles 930, 930′, 930″ are deposited on the fourthside 904, 904′, 904″ of the second substrate 900, 900′, 900″ and thethird side 902, 902′, 902″ of the second substrate 900, 900′, 900″ ispositioned directly adjacent to the first textured substrate 800, 800′,800″, the first and second substrates 800, 800′, 800″, 900, 900′, 900″may be oriented such that the polymer particles 930, 930′, 930″ arelocated on an outer surface 901-A, 901-A′, 901-A″, 901-B, 901-B′. 901-B″of the fibrous structure 901, 901′, 901″.

With reference to FIG. 16A, in one example, the first and secondsubstrates 800, 900 may be oriented such that the first side 802, 902 ofone of the first or the second substrate 800, 900 is facing the secondside 804, 904 of the other of the first or the second substrate 800,900. In particular, the first and second substrates 800, 900 may bepositioned such that the discrete regions 806, 906 of one of the firstor the second substrate 800, 900 are facing the discrete portions 810,910 of the other of the first or the second substrate 800, 900. In theexample shown in FIG. 16A, the first substrate 800 is positioned suchthat the first side 802 of the first substrate 800 is facing the secondside 904 of the second substrate 900, and the first discrete regions 806of the first substrate 800 are facing the second discrete portions 910of the second substrate 900. It is to be understood that the first andsecond substrates 800, 900 as described herein may also be oriented suchthat the first side 902 of the second substrate 900 is facing the secondside 804 of the first substrate 800 and the second discrete regions 906of the second substrate 900 are facing the first discrete portions 801of the first substrate 800.

As shown in FIG. 16B, in another example, the first and secondsubstrates 800′, 900′ may be oriented such that the second side 804′ ofthe first substrate 800′ is facing the second side 904′ of the secondsubstrate 900′. In particular, the first and second substrates 800′,900′ may be positioned such that the first continuous portion 812′ ofthe first substrate 800′ is facing the second continuous portion 912′ ofthe second substrate 900′.

As shown in FIG. 16C, in a further example, the first and secondsubstrates 800″, 900″ may be oriented such that the first side 802″ ofthe first substrate 800″ is facing the first side 902″ of the secondsubstrate 900″. In particular, the first and second substrates 800″,900″ may be positioned such that the first discrete regions 806″ of thefirst substrate 800″ are facing the second discrete regions 906″ of thesecond substrate 900″.

In all examples of textured substrates and fibrous structures describedherein, the polymer particles may comprise at least one raised edge withrespect to the surface of the textured substrate on which the polymerparticle is formed. By slot coating the polymer particles only ontocertain areas of the textured substrate, the amount of raised edge perpolymer particle may be maximized, while minimizing the amount ofpolymer required, controlling the macro-shape of the polymer particles,and preserving other desirable characteristics of the fibrous structure,as described herein. In some examples, the polymer particles maycomprise a perimeter to area ratio of about 1,000 m⁻¹ to about 18,000m⁻¹. In some examples, it is believed that the perimeter to area ratiomay be up to about 36,000 m⁻¹, and in further examples, it is believedthat the perimeter to area ratio may be up to about 54,000 m⁻¹. Thecharacteristics of selected polymer particles according to the presentdisclosure were measured in accordance with the methods described hereinand are set out in the Examples and Table 1 below.

The raised edge(s) of the polymer particles provide enhanced cleaning,preferably without negatively impacting other characteristics of thefibrous structure comprising the textured substrate, such as absorbency,flexibility, and aesthetic properties. With respect to cleaning ofstuck-on, dried, or adhered materials, conventional fibrous structuressuch as paper towels may become overly soft and flexible when wet andrely primarily on dissolving the dried material to loosen and dislodgeit. The polymer particles of the present disclosure are fluid imperviousand retain their ability to mechanically interact with the driedmaterial. Thus, it is believed that fibrous structures according to thepresent disclosure exhibit superior cleaning ability when wet, whilestill retaining the consumer-desirable characteristics of conventionalfibrous structures such as absorbency, tactile feel, visual appearance,etc. The characteristics of selected fibrous structures comprisingtextured substrates according to the present disclosure were measured inaccordance with the methods described herein and are set out in Tables2-4 below.

In all examples described herein, the polymer used to form the polymerparticles may be selected to provide a polymer particle of apredetermined hardness. For example, the polymer particles according tothe present disclosure may comprise a Vickers hardness of between about4 kg/mm² to about 20 kg/mm², which may be measured as described herein.In some particularly examples, the polymer particle may comprise aVickers hardness of about 7 kg/mm². It is believed that a polymerparticle having a greater hardness may enhance the cleaning ability ofthe fibrous structure, while limiting the hardness of the polymerparticles may mitigate the potential of the fibrous structure to causedamage to surfaces during cleaning.

Process for Making Textured Substrates

FIG. 17 illustrates an exemplary process for making a textured substrateaccording to the present disclosure. In one form, a deflection member(not shown) may be used in a papermaking process depicted in FIG. 17 forproducing a textured substrate 500 of the present disclosure. Theprocess comprises the following steps. First, a plurality of fibers 501is provided and is deposited on a forming wire of a papermaking machine,as is known in the art. The present disclosure contemplates the use of avariety of fibers, such as, for example, cellulosic fibers, syntheticfibers, or any other suitable fibers, and any combination thereof.Papermaking fibers useful in the present disclosure include cellulosicfibers commonly known as wood pulp fibers. Fibers derived from softwoods (gymnosperms or coniferous trees) and hard woods (angiosperms ordeciduous trees) are contemplated for use in this disclosure. Theparticular species of tree from which the fibers are derived isimmaterial. The hardwood and softwood fibers may be blended, oralternatively, may be deposited in layers to provide a stratified web.U.S. Pat. Nos. 4,300,981 and 3,994,771 are incorporated herein byreference for the purpose of disclosing layering of hardwood andsoftwood fibers.

The wood pulp fibers may be produced from the native wood by anyconvenient pulping process. Chemical processes such as sulfite, sulfate(including the Kraft), and soda processes are suitable. Mechanicalprocesses such as thermomechanical (or Asplund) processes are alsosuitable. In addition, the various semi-chemical and chemi-mechanicalprocesses may be used. Bleached as well as unbleached fibers arecontemplated for use. When the textured substrate of this disclosure isintended for use in absorbent products such as paper towels, bleachednorthern softwood Kraft pulp fibers may be used. Wood pulps usefulherein include chemical pulps such as Kraft, sulfite and sulfate pulpsas well as mechanical pulps including for example, ground wood,thermomechanical pulps and Chemi-ThermoMechanical Pulp (CTMP). Pulpsderived from both deciduous and coniferous trees may be used.

In addition to the various wood pulp fibers, other cellulosic fiberssuch as cotton linters, rayon, and bagasse may be used in thisdisclosure. Synthetic fibers, such as polymeric fibers, may also beused. Elastomeric polymers, polypropylene, polyethylene, polyester,polyolefin, and nylon, may be used. The polymeric fibers may be producedby spunbond processes, meltblown processes, and other suitable methodsknown in the art. It is believed that thin, long, and continuous fibersproduced by spunbond and meltblown processes may be beneficially used inthe textured substrate of the present disclosure, because such fibersare believed to be easily deflectable into the pockets of the deflectionmember.

The paper furnish may comprise a variety of additives, including but notlimited to fiber binder materials, such as wet strength bindermaterials, dry strength binder materials, chemical softeningcompositions, latexes, bicomponent fibers with a soften-able ormelt-able outer shell, and thermoplastic fibers. Suitable wet strengthbinders include, but are not limited to, materials such aspolyamide-epichlorohydrin resins sold under the trade name of KYMENE™ byHercules Inc., Wilmington, Del. Suitable temporary wet strength bindersinclude but are not limited to synthetic polyacrylates. A suitabletemporary wet strength binder is PAREZ™ marketed by American Cyanamid ofStanford, Conn. Suitable dry strength binders include materials such ascarboxymethyl cellulose and cationic polymers such as ACCO™ 711. TheCYPRO/ACCO family of dry strength materials are available from CYTEC ofKalamazoo, Mich. Forms of fiber bonding may also be utilized, including,but not limited to, carding and hydroentangling.

The paper furnish may comprise a debonding agent to inhibit formation ofsome fiber to fiber bonds as the web is dried. The debonding agent, incombination with the energy provided to the web by the dry crepingprocess, results in a portion of the web being debulked. In one form,the debonding agent may be applied to fibers forming an intermediatefiber layer positioned between two or more layers. The intermediatelayer acts as a debonding layer between outer layers of fibers. Thecreping energy can therefore debulk a portion of the web along thedebonding layer. Suitable debonding agents include chemical softeningcompositions such as those disclosed in U.S. Pat. No. 5,279,767.Suitable biodegradable chemical softening compositions are disclosed inU.S. Pat. Nos. 5,312,522; 5,279,767; and 5,312,522. Such chemicalsoftening compositions can be used as debonding agents for inhibitingfiber-to-fiber bonding in one or more layers of the fibers making up theweb. One suitable softener for providing debonding of fibers in one ormore layers of fibers forming the web is a papermaking additivecomprising DiEster Di (Touch Hardened) Tallow Dimethyl AmmoniumChloride. A suitable softener is ADOGEN® brand papermaking additiveavailable from Witco Company of Greenwich, Conn.

The embryonic web may be typically prepared from an aqueous dispersionof papermaking fibers, though dispersions in liquids other than watermay be used. The fibers are dispersed in the carrier liquid to have aconsistency of from about 0.1 to about 0.3 percent. In yet anotheralternative form, and without being limited by theory, it is believedthat the present disclosure is also applicable to layered wires,structured wires, wet micro contraction, vacuum dewatering, airlaidstructures, including air-laid webs comprising pulp fibers, syntheticfibers, and mixtures thereof.

Conventional papermaking fibers may be used and the aqueous dispersionmay be formed in conventional ways. Conventional papermaking equipmentand processes may be used to form the embryonic web on the Fourdrinierwire. The association of the embryonic web with the deflection membermay be accomplished by simple transfer of the web between the wire andan endless belt, which may define the deflection member, as assisted bydifferential fluid pressure. The fibers may be deflected into thedeflection member/belt by the application of differential fluid pressureinduced by an applied vacuum and/or using a speed differential betweenthe wire and the deflection member/belt. Any technique, such as the useof a Yankee drum dryer, may be used to dry the intermediate web.Foreshortening can be accomplished by any conventional technique such ascreping.

The plurality of fibers may also be supplied in the form of a moistenedfibrous web (not shown), which should preferably be in a condition inwhich portions of the web could be effectively deflected into thedeflection conduits of the deflection member and the void spaces formedbetween the suspended portions and the X-Y plane.

The embryonic web comprising fibers 501 is transferred from a formingwire 123 to a belt 121, which may define the deflection member, via avacuum pick-up shoe 148 a. Alternatively or additionally, a plurality offibers, or fibrous slurry, may be deposited onto the deflection memberdirectly from a headbox or otherwise, including in a batch process, (notshown). The papermaking belt 121 defining the deflection member maytravel past optional dryers/vacuum devices 148 b and 148 c and aboutrolls 119 a, 119 b, 119 k, 119 c, 119 d, 119 e, and 119 f in thedirection schematically indicated by the directional arrow “B”.

Finally, a partly-formed textured substrate associated with thedeflection member may be separated from the deflection member at roll119 k at the transfer to a Yankee dryer 128. By doing so, the deflectionmember, having the fibers thereon, is pressed against a pressingsurface, such as, for example, a surface of a Yankee drying drum 128.After being creped off the Yankee dryer 128, a textured substrate 500results and may be further processed or converted as desired. Thisprocess, alone or in combination with any additional processing step(s),e.g., embossing and/or patterned calendaring, may be used to form any ofthe textured substrates and fibrous structures described herein.

Process for Making Fibrous Structures

FIG. 18 is a flowchart illustrating an exemplary method for forming afibrous structure comprising a textured substrate according to thepresent disclosure. Although reference is made to the components of theslot coater 10 and the textured substrate 100 of FIGS. 2A, 3A, 3B, 9,and 10, it is understood that the method is not limited only to thesestructures. The method may begin at Step 1000 with providing a firsttextured substrate. The first textured substrate may comprise any of thetextured substrates described herein. With reference to FIG. 2A, thefirst textured substrate may be the textured substrate 100 and maycomprise a first side 102 and a second side 104. The first side 102 maycomprise first discrete regions 106 and a first continuous region 108extending between the first discrete regions 106, and the second side104 may comprise a plurality of first discrete portions 110corresponding to the first discrete regions 106 and a first continuousportion 112 corresponding to the first continuous region 108. The methodmay continue at Step 1010 with passing the first textured substrateacross a nozzle of a slot coat header, in which a heated polymer isdispensed from the nozzle. As shown in FIG. 9, a slot coater 10 maycomprise a slot coat header 14 with a nozzle 18 that dispenses a heatedpolymer supplied by a hot melt extruder 16. The textured substrate 100is supported by rollers 20 and is passed across the nozzle 18 of theslot coat header 14.

At step 1020, the heated polymer is deposited onto one of the first sideor the second side of the first textured substrate to form a pluralityof first polymer particles, in which the heated polymer is substantiallydeposited on an area of the first textured substrate that contacts thenozzle such that at least a section of each of the first polymerparticles defines a raised edge. With reference to FIGS. 3A, 3B, 9, and10, one of the first or second sides 102, 104 of the textured substrate100 faces the nozzle 18, and as the textured substrate 100 is passedacross the nozzle 18 of the slot coat header 14, the heated polymer isdeposited on an area of the textured substrate 100 that contacts thenozzle 18 and polymer particles 120 or 130 are formed that define araised edge 122 or 132, as described herein.

The method of FIG. 18 may optionally comprise blocking one or moresections of the nozzle of the slot coat header such that the heatedpolymer is deposited only on one or more sections of the first texturedsubstrate at Step 1030. At step 1040, the first textured substrate isjoined to a second substrate, after which the method may terminate.

With reference to FIGS. 3A and 9 and as described herein, in someexamples, each first discrete region 106 of the first textured substrate100 may comprise an outer section 116 and sidewall sections 118extending outwardly from the adjacent first continuous region 108 to theouter section 116. When the first side 102 is facing the nozzle 18 ofthe slot coat header 14, the heated polymer may be substantiallydeposited onto the first discrete regions 106 such that the firstpolymer particles 130 do not extend to the adjacent first continuousregion 108. In some particular examples, a plurality of the firstdiscrete regions 106 and the corresponding first discrete portions 110may comprise high-density zones 124 and the first continuous region 108and the corresponding first continuous portion 112 may compriselow-density zones 126. In other particular examples, a plurality of thefirst discrete regions 106′ and the corresponding first discreteportions 110′ may comprise low-density zones 126′ and the firstcontinuous region 108′ and the corresponding first continuous portion112′ may comprise high-density zones 124′, as shown in FIG. 3D and asdescribed herein. In further particular examples, depositing the heatedpolymer may comprise depositing the heated polymer only onto the firstdiscrete regions 106, and more particularly, only onto the outersections 116 of the first discrete regions 102. In yet furtherparticular examples, when the second side 104 of the textured substrate100 is facing the nozzle 18 of the slot coat header 14, the heatedpolymer may be deposited onto the first continuous portions 112 suchthat the first polymer particles 130 do not extend to adjacent firstdiscrete portions 110.

In some examples, when the first side 102 of the textured substrate 100is facing the nozzle 14, a plurality of the first polymer particles 120may have generally one of a full ring, a partial ring, or a horseshoeshape, as described herein (see FIGS. 11A-11E). The first polymerparticles 120 having generally the full ring shape may be formed along aperimeter of the outer section 116 of the respective first discreteregion 106, and the first polymer particles 120 having generally thepartial ring or the horseshoe shape may be formed along a segment of theperimeter of the outer section 116 of the respective first discreteregion 106. In some instances, when the first side 102 is facing thenozzle 18, a plurality of the first polymer particles 120 may coversubstantially an entirety of the outer section 116 of the respectivefirst discrete region 106 (see FIG. 11A). In other instances, when thefirst side 102 is facing the nozzle 18, a plurality of the first polymerparticles 120 may comprise an overhang extending from the outer section116 of a respective first discrete region 106, wherein the overhang issubstantially parallel to a first surface plane, e.g., surface plane P₅,of the first textured substrate 100 (see FIGS. 11D and 13). One or morecharacteristics of the polymer particle may be at least partiallycontrolled by at least one of a rheology/rheological profile, surfaceenergy, viscosity, or solidification rate of a polymer comprising theheated polymer, as described herein. One or more characteristics of thepolymer particle may also be at least partially controlled by at leastone of a polymer flow rate, a temperature of the heated polymer and slotcoater components, a contact surface area, a feed speed of the texturedsubstrate, or an amount of cooling applied to the textured substratefollowing formation of the polymer particles, as described herein.

In some aspects, the second substrate may comprise a second texturedsubstrate, which may comprise any of the textured substrates describedherein. The second textured substrate may comprise a third side withsecond discrete regions and a second continuous region extending betweenthe second discrete regions and a fourth side comprising a plurality ofsecond discrete portions corresponding to the second discrete regionsand a second continuous portion corresponding to the second continuousregion. The method for forming the fibrous structure may furthercomprise passing the second textured substrate across the nozzle of theslot coat header, in which the heated polymer is dispensed from thenozzle; and depositing the heated polymer onto one of the third or thefourth side of the second textured substrate to form a plurality ofsecond polymer particles, in which the heated polymer is substantiallydeposited on an area of the second textured substrate that contacts thenozzle, such that at least a section of each of the second polymerparticles defines a raised edge, as described herein (see FIGS. 9 and10).

In some examples, at least one of the first textured substrate or thesecond textured substrate may be embossed as described herein. Embossingmay occur prior to or after depositing the heated polymer to form thefirst and/or second polymer particles. In general, embossing deforms asection of the textured substrate such that the embossed section extendsfurther outward from a surface plane of the textured substrate, ascompared to the non-embossed sections of the textured substrate. Whenembossing occurs after depositing of the heated polymer, one or more ofthe protuberances used to form the embossing pattern may deflect/deforma section of the first and/or second textured substrate on which thefirst and/or second polymer particles are formed, such that the embossedsection extends further outward from the surface plane of the texturedsubstrate, as compared to the non-embossed sections. When embossingoccurs before the heated polymer is deposited, at least a portion of theheated polymer may be deposited on the embossed sections, as thesesections may contact the nozzle, as described herein.

In some instances, the first textured substrate may be joined to thesecond textured substrate such that the first discrete regions of thefirst textured substrate are facing the second discrete portions of thesecond textured substrate, as described herein (see FIG. 16A). In otherinstances, the first textured substrate may be joined to the secondtextured substrate such that the first continuous portion of the firsttextured substrate is facing the second continuous portion of the secondsubstrate, as described herein (see FIG. 16B). In further instances, thefirst textured substrate may be joined to the second textured substratesuch that the first discrete regions of the first textured substrate arefacing the second discrete regions of the second textured substrate, asdescribed herein (see FIG. 16C).

In some instances, the first textured substrate may be joined to thesecond textured substrate such that at least one of the first polymerparticles or the second polymer particles is located within the fibrousstructure, as described herein. In other instances, the first texturedsubstrate may be joined to the second textured substrate such that atleast one of the first polymer particles or the second polymer particlesis located on an outer surface of the fibrous structure, as describedherein. In further instances, the first textured substrate may be joinedto the second textured substrate such that both of the first polymerparticles and the second polymer particles are located within thefibrous structure, as described herein. In yet further instances, thefirst textured substrate may be joined to the second textured substratesuch that both of the first polymer particles and the second polymerparticles are located on an outer surface of the fibrous structure, asdescribed herein (see FIGS. 16A-16C).

In some examples, the method may further comprise applying a coolingairflow following deposition of one or both of the first or the secondpolymer particles, as described herein. Also as described herein, thefibrous structure may comprise two plies, three plies, four plies, fiveplies, etc.

EXAMPLES

Fibrous structures comprising textured substrates according to thepresent disclosure were formed as described below and measurements werecarried out to determine a shape and coverage of polymer particlesformed on the textured substrates.

Example 1

A textured substrate similar to the textured substrate 100 depicted inFIG. 2A is formed, in which polymer particles are deposited on the firstside on the high-density discrete regions. The textured substratecomprising polymer particles is then joined to a second, uncoatedtextured substrate to form a fibrous structure in which the discreteregions of the uncoated textured substrate face the discrete portions ofthe textured substrate comprising the polymer particles. The polymerparticles are on an outside surface of the fibrous structure. Thefibrous structure of this Example would correspond to a fibrousstructure 901 of FIG. 16A, in which the first textured substrate 800 isuncoated and the second textured substrate 900 comprises polymerparticles 920 on the third side 902.

Two, single-ply web substrates are unwound in the machine direction onseparate generally parallel paths. The top substrate is oriented withthe discrete regions facing out, and the bottom substrate is orientedwith the continuous portions facing out.

A polypropylene polymer (Metocene® 650Y, LyondellBasell) is melted in ahot melt extruder (Nordson XP22 single-screw with gear pump) and pumpedto a slot coat header (Nordson SCSE-375) with a heated 17″ slot nozzlecontaining a 343 mm, 150 μm open shim. The slot coat header and nozzleare maintained at 200° C. A polymer flow rate of approximately 0.5grams/second is maintained such that a coating load of approximately 1gram per square meter is achieved with a web feed speed of 300 feet perminute.

The top single-ply web substrate is passed across the nozzle of the slotcoat header with the discontinuous discrete regions being the top-mostcontacting point of the substrate with the nozzle. Due to the topographyof the web substrate, the nozzle deposits molten polymer onto thespecific locations of the web topography that are in closest contactwith the nozzle edge. The deposits occur on the topmost surfaceprotrusions of the web, i.e., the discrete regions and specifically theouter section of the discrete regions. Discrete particles are producedon the web.

The two single-ply webs continue on to the emboss and lamination unitwhere the non-coated substrate is embossed with an emboss roll against apressure roll. This ply then receives glue or adhesive. The coated,second single ply web is brought into contact with the glue adhered sideof the other web and married with a marrying roll into a two-ply sheet.In this Example, the polymer coating creates polymer particles on theoutside of the fibrous structure.

Lines of termination may be added to the advancing substrate to formdiscrete sheets. Thus, a product may be manufactured by rolling,folding, stacking, cutting and placing in a package.

Measurements of the polymer particles formed on the coated substrate aretaken using the methods described herein. The results of thesemeasurements are set out in Table 1 below.

Example 2

A textured substrate similar to the textured substrate 100 depicted inFIG. 2A is formed, in which polymer particles are deposited on the firstside on the high-density discrete regions. The textured substratecomprising polymer particles is then joined to a second, uncoatedtextured substrate to form a fibrous structure in which the discreteregions of the uncoated textured substrate face the discrete regions ofthe textured substrate comprising the polymer particles. The polymerparticles are located within the fibrous structure. The fibrousstructure of this Example would correspond to a fibrous structure 901″of FIG. 16C, in which the first textured substrate 800″ is uncoated andthe second textured substrate 900″ comprises polymer particles 920″ onthe third side 902′.

Two, single-ply web substrates are unwound in the machine direction onseparate generally parallel paths. Both substrates are oriented with thecontinuous portions facing out.

A polypropylene polymer (Metocene® 650Y, LyondellBasell) is melted in ahot melt extruder (Nordson XP22 single-screw with gear pump) and pumpedto a slot coat header (Nordson SCSE-375) with a heated 17″ slot nozzlecontaining a 343 mm, 150 μm open shim. The slot coat header and nozzleare maintained at 200° C. A polymer flow rate of approximately 0.5grams/second is maintained such that a coating load of approximately 1gram per square meter is achieved with a web feed speed of 300 feet perminute.

The bottom single-ply web substrate is passed across the nozzle of theslot coat header with the discrete regions being the top-most contactingpoint of the substrate with the nozzle. Due to the topography of the websubstrate, the nozzle deposits molten polymer onto the specificlocations of the web topography that are in closest contact with thenozzle edge. The deposits occur on the topmost surface protrusions ofthe web, i.e., the discrete regions and specifically the outer sectionof the discrete regions. Discrete particles are produced on the web.

The two single-ply webs continue on to the emboss and lamination unitwhere the coated substrate is embossed with an emboss roll against apressure roll. This ply then receives glue or adhesive on the same sideas the polymer coating. The second, single-ply web is brought intocontact with the glue adhered side of the other web and married with amarrying roll into a two-ply sheet. In this Example, the polymer coatingcreates polymer particles that are on the inside of the texturedsubstrate that first received embossing.

Lines of termination may be added to the advancing substrate to formdiscrete sheets. Thus, a product may be manufactured by rolling,folding, stacking, cutting and placing in a package.

Measurements of the polymer particles formed on the coated substrate aretaken using the method described herein. The results of thesemeasurements are set out in Table 1 below.

Example 3

A textured substrate similar to the textured substrate 100 depicted inFIG. 2A is formed, in which polymer particles are deposited on thesecond side on the low-density continuous portion. The texturedsubstrate comprising polymer particles is then joined to a second,uncoated textured substrate to form a fibrous structure in which thediscrete regions of the uncoated textured substrate face the discreteregions of the textured substrate comprising the polymer particles. Thepolymer particles are on an outside surface of the fibrous structure.The fibrous structure of this Example would correspond to a fibrousstructure 901″ of FIG. 16C, in which the first textured substrate 800″is uncoated and the second textured substrate 900″ comprises polymerparticles 930″ on the fourth side 904″.

Two, single-ply web substrates are unwound in the machine direction onseparate generally parallel paths. Both substrates are oriented with thecontinuous portions facing out.

A polypropylene polymer (Metocene® 650Y, LyondellBasell) is melted in ahot melt extruder (Nordson XP22 single-screw with gear pump) and pumpedto a slot coat header (Nordson SCSE-375) with a heated 17″ slot nozzlecontaining a 343 mm, 150 μm open shim. The slot coat header and nozzleare maintained at 200° C. A polymer flow rate of approximately 0.5grams/second is maintained such that a coating load of approximately 1gram per square meter is achieved with a web feed speed of 300 feet perminute.

The bottom single-ply web substrate is passed across the nozzle of theslot coat header with the continuous portions being the top-mostcontacting point of the substrate with the nozzle. Due to the topographyof the web substrate, the nozzle deposits molten polymer onto thespecific locations of the web topography that are in closest contactwith the nozzle edge, i.e., the continuous portions. The deposits occuron the topmost surface of the web that protrudes outward from thesurface plane of the web. Transfer also occurs around individual fibers.Discrete particles are produced on the web.

The two single-ply webs continue on to the emboss and lamination unitwhere the coated substrate is embossed with an emboss roll against apressure roll. This ply then receives glue or adhesive on the oppositeside as the polymer coating. The second single-ply web is brought intocontact with the glue adhered side of the other web and married with amarrying roll into a two-ply sheet. In this Example, the polymer coatingcreates polymer particles on the outside of the textured substrate thatfirst received embossing.

Lines of termination may be added to the advancing substrate to formdiscrete sheets. Thus, a product may be manufactured by rolling,folding, stacking, cutting and placing in a package.

Measurements of the polymer particles formed on the coated substrate aretaken using the method described herein. The results of thesemeasurements are set out in Table 1 below.

Example 4

A textured substrate similar to the textured substrate 100A depicted inFIG. 2E is formed, in which the low-density continuous portion comprises10% more surface area, as compared to the textured substrates inExamples 1-3, and in which polymer particles are deposited on the secondside on the continuous portion. The textured substrate comprisingpolymer particles is then joined to a second, uncoated texturedsubstrate to form a fibrous structure in which the discrete regions ofthe uncoated textured substrate face the discrete regions of thetextured substrate comprising the polymer particles. The polymerparticles are located on an outside surface of the fibrous structure.The fibrous structure of this Example would correspond to a fibrousstructure 901″ of FIG. 16C, in which the first textured substrate 800″is uncoated and the second textured substrate 900″ comprises polymerparticles 930″ on the fourth side 904″.

Two, single-ply web substrates comprising continuous portions with 10%more contact surface area are unwound in the machine direction onseparate generally parallel paths. Both substrates are oriented with thecontinuous portions facing out.

A polypropylene polymer (Metocene® 650Y, LyondellBasell) is melted in ahot melt extruder (Nordson XP22 single-screw with gear pump) and pumpedto a slot coat header (Nordson SCSE-375) with a heated 17″ slot nozzlecontaining a 343 mm, 150 μm open shim. The slot coat header and nozzleare maintained at 200° C. A polymer flow rate of approximately 0.5grams/second is maintained such that a coating load of approximately 1gram per square meter is achieved with a web feed speed of 300 feet perminute.

The bottom single-ply web substrate is passed across the nozzle of theslot coat header with the continuous portion being the top-mostcontacting point of the substrate with the nozzle. Due to the topographyof the web substrate, the nozzle deposits molten polymer onto thespecific locations of the web topography that are in closest contactwith the nozzle edge, i.e., the continuous portions. The deposits occuron the topmost surface of the web that protrudes outward from thesurface plane of the web. Transfer also occurs around individual fibers.Discrete particles are produced on the web.

The two single-ply webs continue on to the emboss and lamination unitwhere the coated substrate is embossed with an emboss roll against apressure roll. This ply then receives glue or adhesive on the oppositeside as the polymer coating. The second single-ply web is brought intocontact with the glue adhered side of the other web and married with amarrying roll into a two-ply sheet. In this Example, the polymer coatingcreates polymer particles on the outside of the textured substrate thatfirst received embossing.

Lines of termination may be added to the advancing substrate to formdiscrete sheets. Thus, a product may be manufactured by rolling,folding, stacking, cutting and placing in a package.

Measurements of the polymer particles formed on the coated substrate aretaken using the method described herein. The results of thesemeasurements are set out in Table 1 below.

Example 5

A first textured substrate similar to the textured substrate 100depicted in FIG. 2A is formed, in which first polymer particles aredeposited on the first side on the high-density first discrete regions.The first textured substrate is then joined to a second, texturedsubstrate having a similar configuration in which second polymerparticles are deposited on the high-density second discrete regions. Afibrous structure is formed in which the continuous portions of thefirst textured substrate face the continuous portions of the secondtextured substrate. The polymer particles are on both outside surfacesof the fibrous structure. The fibrous structure of this Example wouldcorrespond to a fibrous structure 901′ of FIG. 16B, in which the firsttextured substrate 800′ comprises polymer particles 820′ on the firstside 802′ and the second textured substrate 900′ comprises polymerparticles 920′ on the third side 902′.

One, single ply web is unwound in the machine direction and orientedwith the discrete regions facing out.

A polypropylene polymer (Metocene® 650Y, LyondellBasell) is melted in ahot melt extruder (Nordson XP22 single-screw with gear pump) and pumpedto a slot coat header (Nordson SCSE-375) with a heated 17″ slot nozzlecontaining a 343 mm, 150 μm open shim. The slot coat header and nozzleare maintained at 200° C. A polymer flow rate of approximately 0.5grams/second is maintained such that a coating load of approximately 1gram per square meter is achieved with a web feed speed of 300 feet perminute.

The single-ply textured substrate is passed across the nozzle of theslot coat header with the discrete regions being the top-most contactingpoint of the substrate with the nozzle. Due to the topography of the websubstrate, the nozzle deposits molten polymer onto the specificlocations of the web topography that are in closest contact with thenozzle edge. The deposits occur on the top most surface protrusions ofthe web, i.e., the first discrete regions and specifically the outersection of the first discrete regions. Transfer also occurs around theedge and on the leading edge of the protrusions. Discrete particles areproduced on the web.

The single-ply coated (first) web is rewound on a parent roll core. Thissingle-ply roll is returned to the bottom unwind stand and placed so asto unwind with the protrusions, i.e., the discrete regions, facing out.A second uncoated single-ply textured substrate is placed in the topunwind stand and oriented to unwind with the discrete regions facingout. Both substrates are unwound in the machine direction on separategenerally parallel paths.

The top single-ply web substrate is passed across the nozzle of the slotcoat header with the discrete regions being the top-most contactingpoint of the substrate with the nozzle. Due to the topography of the websubstrate, the nozzle deposits molten polymer onto the specificlocations of the web topography that are in closest contact with thenozzle edge. The deposits occur on the top most surface protrusions ofthe web, i.e., the second discrete regions and specifically the outersection of the second discrete regions. Transfer also occurs around theedge and on the leading edge of the protrusions. Discrete particles areproduced on the web.

The two single-ply coated webs continue on to the emboss and laminationunit where the bottom (first) web substrate is embossed with an embossroll against a pressure roll. This ply then receives glue or adhesive onthe opposite side as the polymer coating. The second single-ply web isbrought into contact with the glue adhered side of the other web. Thesecond web is also oriented so the glue contacts the side opposite thepolymer coating. The two plies are married with a marrying roll into atwo-ply sheet. In this Example the polymer coating creates polymerparticles that are on both of the outside surfaces of the two-plyfibrous structure.

Lines of termination may be added to the advancing substrate to formdiscrete sheets. Thus, a product may be manufactured by rolling,folding, stacking, cutting and placing in a package.

Methods for Measuring Polymer Particle Shape and Coverage

Polymer particles formed as described in Examples 1-4 above arecharacterized by analyzing an image of the substrate prototype in whichthe polymer material is visually distinct from the supporting substrate.

Methods to produce such an image may include:

(1) adding a UV tracer (such as Tinopal OB, ex. BASF at 0.5 g/kgpolymer) to the polymer blend prior to the melting and coating process.The substrate can be captured in a UV light box (such as a UV-capableDigiEye, ex. Verivide, UK) with a camera and macro lens mounted (such asa Nikon D7000 with Sigma 105 mm DG Macro MSM lens) using exposuresettings that are appropriate for the tracer level (such as ISO 500, 2.5s shutter speed, f2.5 aperture, active D lighting disabled, capturing aRAW image) and a fixed focus at the appropriate focal length for thesubstrate; or

(2) NIR mapping of the image using a suitable instrument (such as theHyperion 3000 from Bruker).

If needed, the ply and side of the substrate that comprises the polymercoating must first be exposed to the imaging device prior to capture,including separating the plies if the polymer coating is within thelaminated structure.

Analysis of the images can be conducted using appropriate particle imageanalysis software such as that provided with the Morphologi G3 particleanalyzer instrument (ex. Malvern Instruments, UK); using the MeasureImage File functionality, with the following settings for the aboveimage example: version 8.12, inverted image, lower threshold 0, upperthreshold 80, particles of more than 25 pixels included in analysis,Analysis ID 3.00, hole-filling disabled.

Measurement of the total substrate image area is calculated from imagingof a distance standard and calibration vs. pixel size. Microns per pixelis calculated as (horizontal width of distance standard visible in imagein millimeters)/(horizontal length of image in pixels)×1000.

Size and shape parameters of each two-dimensional particle projection(with x and y axes in the same plane as the paper substrate) identifiedby the image analysis are calculated using the ID 3.00 algorithm of theMorphologi software (v. 8.12, Malvern, UK).

The Circle-Equivalent Diameter (CED), or Area-Equivalent Diameter (ISO9276-6:2008(E) section 7), or Equivalent Circle Diameter (ASTM F1877-05Section 11.3.2) is defined as the diameter of the circle that would havethe equivalent area to the particle projection.

Solidity is a quantitative, two-dimensional image analysis shapedescription, described by ISO 9276-6:2008(E) section 8.2. Solidityvalues range from 0 to 1, where a solidity number of 1 describes anon-concave particle projection (such as a circle), as measured inliterature as being:

Solidity=A/Ac

where A is the area of the particle and Ac is the area of the convexhull (envelope) of bounding the particle. The solidity decreases towardszero with increasing ‘spikiness’ of the particle.

Convexity is another quantitative measure (described in ISO 9276-6),which describes how ‘spiky’ the particle projection is (convexity=Pc/P,where P is the length of the perimeter of the particle and P_(C) islength of the perimeter of the convex hull (envelope) bounding theparticle).

Circularity is a quantitative, two-dimensional image analysis shapeparameter described by ISO 9276-6:2008(E) section 8.2, describing theratio of the circumference of a circle equal to the object's projectedarea to the perimeter of the object. This can be represented by:

$C = \sqrt{\frac{4\;\pi\; A}{P^{2}}}$

where A is projection area and P is the length of the perimeter of theparticle projection. Circularity values range from 0 to 1, where acircularity of 1 describes a perfectly circular projection.

Edge or perimeter to area ratio is defined as: ((number-based meanperimeter of particles analyzed)×(number of particlesanalyzed))/((number-based mean projected area of particlesanalyzed)×(number of particles analyzed)).

Particle coverage describes the proportion of the surface plane that iscoated with polymer particles and is defined as: ((number-based meanprojected area of particles analyzed)×(number of particlesanalyzed))/(total substrate area of samples analyzed).

Aspect ratio of a particle is calculated as particle width/particlelength. Width and length are defined as follows: The major axis passesthrough the center of mass of the object at an orientation correspondingto the minimum rotational energy of the shape. It is also termed theorientation. The minor axis passes through the center of mass at rightangles to the major axis. Lines from all points on the perimeter areprojected onto the major axis of the particle. The longest distancebetween the points where two of these projections meet the axis isdefined as the length of the particle. Lines from all points on theperimeter are projected onto the minor axis of the particle. The longestdistance between the points where two of these projections meet the axisis defined as the width of the particle.

In each of these measurements, multiple analyses may be conducted acrossmultiple images or replicates, with particle statistics and substrateareas being combined as appropriate.

For each of these parameters, distributions from multiple replicateimages are combined to a single distribution, and area-weighted meansare analyzed and reported. The results of these measurements are set outin Table 1 below.

TABLE 1 CE Diameter Aspect Particle Perimeter/ (μm) CircularityConvexity Solidity Ratio coverage % Area [m⁻¹] Example 1 1063 0.81 0.930.93 0.72 14.9% 7024 Example 2 743 0.81 0.94 0.92 0.70 9.7% 8954 Example3 400 0.77 0.95 0.93 0.68 1.3% 17823 Example 4 1980 0.75 0.92 0.90 0.6720.6% 7881 Control (no N/A N/A N/A N/A N/A 0.0% N/A polymer)

Tables 2-4 below sets out performance data for several texturedsubstrates according to the present disclosure. One to three samples ofeach textured substrate were tested. In Tables 2-4, the fibrousstructures of Examples 1-1, 1-2, and 1-3 comprise the structure set outin Example 1 above; the fibrous structure of Examples 2-1, 2-2, and 2-3comprise the structure set out in Example 2 above; the fibrous structureof Examples 3-1 and 3-2 comprise the structure set out in Example 3above; and the fibrous structures of Examples 4-1 and 4-2 correspond tothe structure set out in Example 4 above.

The fibrous structures of Example 5 in Tables 2-4 comprise a texturedsubstrate similar to the textured substrate 100′ of FIG. 2B, in whichpolymer particles are deposited on the first side on the low-densitydiscrete regions. The textured substrate comprising polymer particles isjoined to a second, uncoated substrate such that the discrete regions ofthe textured substrate comprising the polymer particles face thediscrete regions of the uncoated textured substrate and the polymerparticles are located within the fibrous structure. The fibrousstructures of Example 5 would correspond to a fibrous structure 901″ ofFIG. 16C in which the first textured substrate 800″ is uncoated and thesecond textured substrate 900″ comprises polymer particles 920″ on thethird side 902″.

The fibrous structures of Example 6 comprise a textured substratesimilar to the textured substrate 100′ of 2B, in which polymer particlesare deposited on the second side on the high-density continuousportions. The textured substrate comprising polymer particles is joinedto a second, uncoated substrate such that the discrete regions of thetextured substrate comprising the polymer particles face the discreteregions of the uncoated textured substrate and the polymer particles arelocated on an outside surface of the fibrous structure. The fibrousstructures of Example 6 would correspond to a fibrous structure 901″ ofFIG. 16C in which the first textured substrate 800″ is uncoated and thesecond textured substrate 900″ comprises polymer particles 930″ on thefourth side 904″.

The fibrous structures of Example 7 comprise a textured substratesimilar to the textured substrate 100′ of 2B, in which polymer particlesare deposited on the first side on the low-density discrete regions. Thetextured substrate comprising polymer particles is joined to a second,uncoated substrate such that the discrete regions of the uncoatedsubstrate face the discrete portions of the textured substratecomprising the polymer particles. The polymer particles are on anoutside surface of the fibrous structure. The fibrous structures ofExample 7 would correspond to a fibrous structure 901 of FIG. 16A, inwhich the first textured substrate 800 is uncoated and the secondtextured substrate 900 comprises polymer particles 920 on the third side902.

The fibrous structure of Example 8 comprises a textured substratesimilar to the textured substrate 100A depicted in FIG. 2E, in which thelow-density continuous portion comprises 10% more surface area, ascompared to the textured substrates in the other Examples, and in whichpolymer particles are deposited on the first side on the high densitydiscrete regions. The textured substrate comprising polymer particles isthen joined to a second, uncoated textured substrate to form a fibrousstructure in which the discrete regions of the uncoated texturedsubstrate face the discrete portions of the textured substratecomprising the polymer particles. The polymer particles are located onan outside surface of the fibrous structure. The fibrous structure ofExample 8 would correspond to a fibrous structure 901 of FIG. 16A, inwhich the second textured substrate 900 is uncoated and the firsttextured substrate 800 comprises polymer particles 820 on the first side802.

The fibrous structures of Example 9 comprise a textured substrate inwhich a width (see FIG. 2E) of the high-density discrete regions hasbeen decreased but a number of the discrete regions has been increasedsuch that the contact surface area comprising the discrete regionsremains substantially the same as compared to the textured substrates inthe other Examples, and in which polymer particles are deposited on thefirst side on the high density discrete regions. The textured substratecomprising polymer particles is then joined to a second, uncoatedtextured substrate to form a fibrous structure in which the discreteregions of the uncoated textured substrate face the discrete portions ofthe textured substrate comprising the polymer particles. The polymerparticles are located on an outside surface of the fibrous structure.The fibrous structures of Example 9 would correspond to a fibrousstructure 901 of FIG. 16A, in which the first textured substrate 800 isuncoated and the second textured substrate 900 comprises polymerparticles 920 on the first side 902.

The fibrous structures of Example 10 comprise a textured substrate inwhich a width (see FIG. 2E) of the high-density discrete regions hasbeen decreased but a number of the discrete regions has been increasedsuch that the contact surface area comprising the discrete regionsremains substantially the same as compared to the textured substrates inthe other Examples, and in which polymer particles are deposited on thefirst side on the high density discrete regions. The textured substratecomprising polymer particles is then joined to a second, uncoatedtextured substrate to form a fibrous structure in which the discreteregions of the uncoated textured substrate face the discrete regions ofthe textured substrate comprising the polymer particles. The polymerparticles are located within the fibrous structure. The fibrousstructures of Example 10 would correspond to a fibrous structure 901″ ofFIG. 16C, in which the first textured substrate 800″ is uncoated and thesecond textured substrate 900″ comprises polymer particles 920″ on thethird side 902″.

The fibrous structure of Example 11 comprises a textured substrate inwhich a width (see FIG. 2E) of the high-density discrete regions hasbeen decreased but a number of the discrete regions has been increasedsuch that the contact surface area comprising the discrete regionsremains substantially the same as compared to the textured substrates inthe other Examples, and in which polymer particles are deposited on thesecond side on the low-density continuous portions. The texturedsubstrate comprising polymer particles is then joined to a second,uncoated textured substrate to form a fibrous structure in which thediscrete regions of the uncoated textured substrate face the discreteregions of the textured substrate comprising the polymer particles. Thepolymer particles are located on an outside surface of the fibrousstructure. The fibrous structures of Example 11 would correspond to afibrous structure 901″ of FIG. 16C, in which the first texturedsubstrate 800″ is uncoated and the second textured substrate 900″comprises polymer particles 930″ on the fourth side 904″.

TABLE 2 Cleaning Performance Data Polymer vs PPM Mach 7 vs. BW CRT CRTLoad Equivalent uncoated #/3000 Rate Capacity (gsm) (*** M7 off-shelf)same sqft g/s g/sqin Example 1-1 0 131% 100% 31.2 0.49 0.62 Example 1-20.5 207% 158% Example 1-3 1 263% 201% 32 0.52 0.63 Example 2-1 0 132%100% Example 2-2 0.5 143% 109% Example 2-3 1 182% 138% 31.5 0.53 0.65Example 3-1 0 100% 100% Example 3-2 1 138% 138% 31.3 0.54 0.63 Example4-1 0 100% 100% Example 4-2 1 237% 236% Example 5-1 0 111% 100% 33.20.56 0.68 Example 5-2 1 147% 132% 33.1 0.49 0.68 Example 6 1 213% 222%32.8 0.53 0.68 Example 7-1 0 137% 100% 32 0.41 0.68 Example 7-2 1 213%155% 32.7 0.57 0.71 Example 8-1 1 258% 188% 31.7 0.56 0.59 Example 9-1 0139% 100% 31.4 0.43 0.62 Example 9-2 1 244% 176% 32 0.45 0.62 Example10-1 0 107% 100% 31.3 0.48 0.66 Example 10-2 1 108% 101% 32.2 0.38 0.65Example 11 1 103% 126% 32.4 0.46 0.64

TABLE 3 Performance Data (Cont'd) CRT Dry Wet COF Capacity caliper,caliper, COF Slip Kinetic- g/sheet mils mils Stick-out out Example 1-175.2 39.3 32.1 809 1.12 Example 1-2 Example 1-3 76.2 39.4 31.3 1021 1.17Example 2-1 893 1.12 Example 2-2 Example 2-3 77.7 39.3 31.3 792 1.01Example 3-1 Example 3-2 75.8 39.8 31 866 1.11 Example 4-1 846 1.06Example 4-2 885 1.07 Example 5-1 81.7 38.1 29.8 927 1.04 Example 5-2 8239 30.3 838 Example 6 82 38 29.6 997 Example 7-1 81.7 37.6 29.6 1.05Example 7-2 85.6 37.8 29.7 1.12 Example 8-1 71.7 36.1 31.3 703 1.15Example 9-1 75.9 40.1 30.1 874 1.13 Example 9-2 74.2 39.7 30 891 1.17Example 10-1 79.2 41.2 31.6 Example 10-2 78.5 41.7 31.5 933 1.17 Example11 76.6 42.5 32.4 865 1.16

TABLE 4 Performance Data (Cont'd) COF Slip COF SST Stick-in Kinetic-in(g/sec^(0.5)) Example 1-1 1608 1.14 1.7 Example 1-2 Example 1-3 879 0.761.63 Example 2-1 807 1.16 1.69 Example 2-2 Example 2-3 1031 1.31 1.74Example 3-1 1.75 Example 3-2 821 1.10 1.64 Example 4-1 925 1.05 1.77Example 4-2 877 1.04 2 Example 5-1 883 0.92 1.71 Example 5-2 Example 61.65 Example 7-1 1189 0.82 1.56 Example 7-2 811 1.19 1.89 Example 8-1876 1.03 1.79 Example 9-1 1081 0.94 1.77 Example 9-2 1151 0.84 1.88Example 10-1 Example 10-2 873 1.21 1.69 Example 11 973 1.20 1.53

In all Examples, the addition of polymer particles resulted in at leastsome improvement in cleaning ability as compared to the equivalentuncoated fibrous structure and to an off-the-shelf product. Inparticular, Examples 1-2, 1-3, 2-2, 2-3, 3-2, and 4-2 exhibitedsignificant improvements in cleaning ability, and in some instances, thefibrous structures with polymer particles demonstrated a two-foldincrease in cleaning ability. In addition, the coefficient of friction(COF) metrics may be correlated to softness, i.e., a pleasing tactilefeel of the fibrous structure. As shown in Tables 3 and 4, “COF slipstick-out” (top side of sheet) and “COF slip stick-in” (back side ofsheet) are substantially equivalent, despite the presence of polymerparticles deposited on one of these faces, which indicates that cleaningis improved and softness is maintained, even in the presence of thepolymer particles. The COF slip stick-in of all Examples comprisingpolymer particles is lower than the COF slip stick-in of Example 1-1,which is an uncoated fibrous structure with the discrete regions facingout. Furthermore, the CRT rate, CRT capacity, and SST (all of whichrelate to absorbency) are substantially unchanged for many Examples,with respect to uncoated, which indicates that the presence of polymerparticles has little or no negative impact on absorbency. Dry caliperand wet caliper are similarly unaffected by the presence of polymerparticles.

Process for Measuring Polymer Particle Hardness:

The Vickers hardness is measured at 23° C. according to standard methodsISO 14577-1, ISO 14577-2, and ISO 14577-3. The Vickers hardness ismeasured from a solid block of the raw material at least 2 mm inthickness. The Vickers hardness micro indentation measurement is carriedout by using the Micro-Hardness Tester (MHT; manufactured by CSMInstruments SA, Peseux, Switzerland). As per the ISO 14577 instructions,the test surface should be flat and smooth, having a roughness (Ra)value less than 5% of the maximum indenter penetration depth. For a 200μm maximum depth, this equates to a Ra value less than 10 μm. As per ISO14577, such a surface may be prepared by any suitable means, which mayinclude cutting the block of test material with a new sharp microtome orscalpel blade, grinding, polishing, or by casting melted material onto aflat, smooth casting form and allowing it to thoroughly solidify priortesting.

Suitable general settings for the Micro-Hardness Tester (MHT) are asfollows:

Control mode: Displacement, Continuous

Maximum displacement: 200 μm Approach speed: 20 nm/s

Zero point determination: at contact

Hold period to measure thermal drift at contact: 60 s

Force application time: 30 s

Frequency of data logging: at least every second

Hold time at maximum force: 30 s

Force removal time: 30 s

Shape/Material of intender tip: Vickers Pyramid Shape/Diamond Tip

Process for Measuring Cleaning Performance

The tiles (typically glossy, white, ceramic 24 cm×4 cm, such as thoseavailable from Emaillerie, Belgium) are covered with 0.3 g of typicalgreasy soap scum soils mainly based on calcium stearate and artificialbody soils (such as those commercially available from Equest, Consett,UK) and a small quantity of graphite powder or blue pigment to increaseopacity (applied to the tile via spraying with solvent using aconsumer-grade airbrush). The soiled tiles are then dried in an oven ata temperature of 140° C. for 10-45 minutes, preferably 40 minutes andthen aged between 2 and 12 hours at room temperature (around 20° C.) ina controlled environment humidity (60-85% RH, preferably 75% RH).

A Wet Abrasion Scrub Tester Instrument (such as made by SheenInstruments Ltd. Kingston, England) is used to clean the tiles. Strips(180×40 mm) of the substrates being tested are affixed to the foursponge holders, using semi-rigid rubber backing pieces with bevellededges (in turn mounted on sponges of approximately 20 mm thickness). Thestrips are held in place using small magnets on the side of the spongeholder. An amount of cleaning fluid (2 ml of commercially availableFlash Kitchen, UK) is added to each substrate using a syringe. Thesponge holder is configured with 200 g of additional mass per sample,then mounted in the Wet Abrasion Scrub Tester. The tile is cleaned at ascrub rate of 37 cycles per minute over a stroke length of 300 mm.

The number of wipes required to clean a stripe in the soil by eachsubstrate is assessed either visually by the operator, or using anautomated camera mounted above the sample on which colour-based imageanalysis is conducted. The cleaning performance of a substrate, referredto as the cleaning index, is defined as the number of wipes required toclean by the reference substrate divided by the number of wipes requiredto clean by the test substrate, multiplied by 100. If this cleaningindex is greater than 100, then the test substrate cleaning is fasterthan that of the reference substrate.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross-referenced or relatedpatent or application is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany form disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such form. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shouldgovern.

While particular aspects of the present disclosure have been illustratedand described, it would be obvious to those skilled in the art thatvarious other changes and modifications may be made without departingfrom the spirit and scope of the present disclosure. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this disclosure.

What is claimed is:
 1. A fibrous structure comprising first and secondplies, wherein: the first ply comprises a first textured substratecomprising: a first side comprising first discrete regions and a firstcontinuous region extending between the first discrete regions, eachfirst discrete region comprising an outer section and sidewall sectionsextending outwardly from the adjacent first continuous region to theouter section; a second side comprising first discrete portionscorresponding to the first discrete regions and a first continuousportion corresponding to the first continuous region; and first polymerparticles deposited on at least one of the first side or the secondside, wherein: when the first polymer particles are deposited on thefirst side, the first polymer particles are substantially deposited onthe outer sections of the first discrete regions and do not extend tothe adjacent first continuous region; when the first polymer particlesare deposited on the second side, the first polymer particles aresubstantially deposited on the first continuous portion and do notextend to the adjacent first discrete portions; and at least a sectionof each of the first polymer particles defines a raised edge; and thesecond ply comprises a second substrate joined to the first texturedsubstrate.
 2. The fibrous structure of claim 1, wherein: when the firstpolymer particles are deposited on the first side of the first texturedsubstrate and the first side of the first textured substrate ispositioned directly adjacent to the second substrate, the first polymerparticles are located within the fibrous structure.
 3. The fibrousstructure of claim 1, wherein: when the first polymer particles aredeposited on the first side of the first textured substrate and thesecond side of the first textured substrate is positioned directlyadjacent to the second substrate, the first polymer particles arelocated on an outer surface of the fibrous structure.
 4. The fibrousstructure of claim 1, wherein: when the first polymer particles aredeposited on the second side of the first textured substrate and thesecond side of the first textured substrate is positioned directlyadjacent to the second substrate, the first polymer particles arelocated within the fibrous structure.
 5. The fibrous structure of claim1, wherein: when the first polymer particles are deposited on the secondside of the first textured substrate and the first side of the firsttextured substrate is positioned directly adjacent to the secondsubstrate, the first polymer particles are located on an outer surfaceof the fibrous structure.
 6. The fibrous structure of claim 1, whereinwhen the first polymer particles are deposited on the first side, thefirst polymer particles are deposited only on the first discreteregions.
 7. The fibrous structure of claim 6, wherein each of the firstpolymer particles is deposited only on the outer sections of the firstdiscrete regions.
 8. The fibrous structure of claim 1, wherein when thefirst polymer particles are deposited on the second side, the firstpolymer particles are deposited only on the first continuous portion. 9.The fibrous structure of claim 1, wherein a plurality of the firstdiscrete regions and the corresponding first discrete portions comprisehigh-density zones and the first continuous region and the correspondingfirst continuous portion comprise a low-density zone.
 10. The fibrousstructure of claim 1, wherein a plurality of the first discrete regionsand the corresponding first discrete portions comprise low-density zonesand the first continuous region and the corresponding first continuousportion comprise a high-density zone.
 11. The fibrous structure of claim1, wherein the second substrate comprises: a third side comprisingsecond discrete regions and a second continuous region extending betweenthe second discrete regions, each second discrete region comprising anouter section and sidewall sections extending outwardly from theadjacent second continuous region to the outer section; a fourth sidecomprising second discrete portions corresponding to the second discreteregions and a second continuous portion corresponding to the secondcontinuous region; and second polymer particles deposited on at leastone of the third side or the fourth side, wherein: when the secondpolymer particles are deposited on the third side, the second polymerparticles are substantially deposited on the outer sections of thesecond discrete regions and do not extend to the adjacent secondcontinuous region; when the second polymer particles are deposited onthe fourth side, the second polymer particles are deposited on thesecond continuous portion and do not extend to an adjacent seconddiscrete portion; and at least a section of each of the second polymerparticles defines a raised edge.
 12. The fibrous structure of claim 11,wherein the first textured substrate is positioned such that the firstdiscrete regions of the first textured substrate are facing the seconddiscrete portions of the second substrate.
 13. The fibrous structure ofclaim 11, wherein the first textured substrate is positioned such thatthe first continuous portion of the first textured substrate is facingthe second continuous portion of the second substrate.
 14. The fibrousstructure of claim 11, wherein the first textured substrate ispositioned such that the first discrete regions of the first texturedsubstrate are facing the second discrete regions of the secondsubstrate.
 15. The fibrous structure of claim 11, wherein: when thesecond polymer particles are deposited on the third side of the secondsubstrate and the third side of the second substrate is positioneddirectly adjacent to the first textured substrate, the second polymerparticles are located within the fibrous structure.
 16. The fibrousstructure of claim 11, wherein: when the second polymer particles aredeposited on the third side of the second substrate and the fourth sideof the second substrate is positioned directly adjacent to the firsttextured substrate, the second polymer particles are located on an outersurface of the fibrous structure.
 17. The fibrous structure of claim 11,wherein: when the second polymer particles are deposited on the fourthside of the second substrate and the fourth side of the second substrateis positioned directly adjacent to the first textured substrate, thesecond polymer particles are located within the fibrous structure. 18.The fibrous structure of claim 11, wherein: when the second polymerparticles are deposited on the fourth side of the second substrate andthe third side of the second substrate is positioned directly adjacentto the first textured substrate, the second polymer particles arelocated on an outer surface of the fibrous structure.
 19. The fibrousstructure of claim 11, wherein when the second polymer particles aredeposited on the third side, the second polymer particles are depositedonly on the second discrete regions.
 20. The fibrous structure of claim19, wherein each of the second polymer particles is deposited only onthe outer sections of the second discrete regions.
 21. The fibrousstructure of claim 11, wherein when the second polymer particles aredeposited on the fourth side, the second polymer particles are depositedonly on the second continuous portion.
 22. The fibrous structure ofclaim 11, wherein a plurality of the second discrete regions and thecorresponding second discrete portions comprise high-density zones andthe second continuous region and the corresponding second continuousportion comprise a low-density zone.
 23. The fibrous structure of claim11, wherein a plurality of the second discrete regions and thecorresponding second discrete portions comprise low-density zones andthe second continuous region and the corresponding second continuousportion comprise a high-density zone.